Non-bromine, non-chlorine flame retardant, glass filled polycarbonate with improved multi-axial impact strength

ABSTRACT

In various aspects, the disclosure relates to polycarbonate compositions exhibiting improved impact strength, both multi axial and notched Izod, as well as thin-walled flame resistance while free or substantially free of bromine or chlorine flame retardant additives. The polycarbonate compositions may comprise non-bonding glass fiber, butyl tosylate, and/or a phosphorous based stabilizer.

CROSS-REFERENCE TO RELATED APPLICATION

This application is the National Stage of International Application No.PCT/IB2018/052875 filed Apr. 25, 2018, which claims the benefit of U.S.Provisional Application No. 62/489,503 filed Apr. 25, 2017, thedisclosures of which are incorporated herein by this reference in theirentireties.

TECHNICAL FIELD

The disclosure concerns glass filled polycarbonate compositions havingnon-brominated and/or chlorinated flame retardant additives andexhibiting improved impact strength.

BACKGROUND

Polycarbonate polymers are useful in a number of material applicationshave an array of advantageous physical properties and mechanicalproperties including, for example, high impact strength, excellentdimensional stability, glass-like transparency, excellent thermalresistance, and low-temperature toughness. These properties, amongothers, make polycarbonates desirable for a similarly wide variety ofapplications including, for example, construction, automotive andtransportation, electrical and electronics, telecommunication,packaging, medical, optical/opthalmic, and optical media. Polycarbonatematerials are often processed with other materials to improve theirphysical performance. For example, polycarbonates may be combined withother polymers that function as impact modifiers to produce a moreresilient material. In further examples, fillers and others reinforcingadditives are introduced to a polycarbonate polymer matrix to enhanceproperties such as modulus and impact strength. In various applications,flame-retardancy is an important property, for example, in electricaland electronics applications, such as appliance and equipment housingsand parts. Ideally, these flame retardant polycarbonate materialsexhibit both robust flame retardance and thin walled resilience.Industry standards increasingly require that the flame retardant is freeof halogen, particularly bromine. There remains a need in the art forpolycarbonate compositions that exhibit good processability and thinwall flame retardancy, while also maintaining impact strength.

SUMMARY

In an aspect, the present disclosure, provides filled compositionscomprising: from about 70 weight percent (wt. %) to about 98 wt. % of apolycarbonate polymer component; from about 0.01 to about 1 wt. % of aflame retardant additive, wherein the flame retardant additive is freeor substantially free of bromine and/or chlorine; and from about 2 toabout 20 wt. % of a non-bonding glass fiber; from about 0.001 wt. % toabout 5 wt. % of a stabilizer additive component, wherein the stabilizeradditive component comprises butyl tosylate, wherein a molded sampleformed from the composition exhibits a multi-axial impact (MAI) ratingenergy at max force of greater than about 60 Joules (J) when tested inaccordance with ISO6603 standard and wherein a molded sample of thecomposition achieves a V1 rating at a thickness of about 0.8 millimeter(mm) and a flame out time of less than about 60 seconds when tested inaccordance with UL 94.

In another aspect, the present disclosure relates to A compositioncomprising: from about 70 wt. % to about 98 wt. % of a polycarbonatepolymer component; from about 0.01 wt. % to about 1 wt. % of a flameretardant additive, wherein the flame retardant additive is free orsubstantially free of bromine and/or chlorine; from about 2 wt. % toabout 20 wt. % of a non-bonding glass fiber; and from about 0.01 wt. %to about 5 wt. % of a stabilizer component wherein the stabilizercomponent comprises one or more of bis (2,4-dicumylphenyl)pentaerythritol diphosphite ortetrakis(2,4-di-tert-butylphenyl)-4,4-biphenyldiphosphonite (PEPQ),wherein a molded sample formed from the composition exhibits a MAIrating energy at max force of greater than about 60 Joules at 23 degreesCelsius (° C.) when tested in accordance with ISO6603 standard andwherein a molded sample of the composition achieves a V2 rating at athickness of about 0.8 millimeter (mm) UL 94.

Furthermore, this disclosure relates to a method comprising: from about70 wt. % to about 98 wt. % of a polycarbonate polymer component; fromabout 0.01 to about 1 wt. % of a flame retardant additive, wherein theflame retardant additive is free or substantially free of bromine and/orchlorine; and from about 2 to about 20 wt. % of a non-bonding glassfiber; and from about 0.001 to about 5 wt. % of a stabilizer additivecomponent, wherein the stabilizer additive component comprises butyltosylate, wherein the butyl tosylate and non-bonding glass fiber arepresent in a ratio of from about from about 1:1000 to about 1:3000 ofbutyl tosylate to non-bonding glass fiber.

In another aspect, the disclosure concerns an article prepared accordingto the methods of forming a composition as disclosed herein or anarticle formed from the compositions disclosed herein.

BRIEF DESCRIPTION OF THE FIGURES

The above-mentioned and other features and advantages of thisdisclosure, and the manner of attaining them, will become apparent andbe better understood by reference to the following description of oneaspect of the disclosure in conjunction with the accompanying drawings,wherein:

FIG. 1 presents Table 1 showing the components of the thermoplasticcomposition.

FIG. 2 presents Table 2 showing the characteristics of the glass fiber.

FIG. 3 presents Table 5 showing the thermoplastic compositions withglass fiber.

FIG. 4 presents Table 6A showing the polycarbonate compositions withnon-bonding glass fiber.

FIG. 5 presents Table 6B showing the performance of the polycarbonatecompositions with non-bonding glass fiber.

DETAILED DESCRIPTION

Polycarbonate materials are often processed with other materials toimprove their physical performance. Flame retardant additives may beincluded so that the polycarbonate resists flames making the materialmore useful for certain applications. Demand for non-brominated flameretardant additives has increased because these additives avoid releaseof certain halogenated chemicals when the matrix polymer is underenvironmental stresses that may cause degradation, melting, or burning.The market trend in Europe and Pacific for electrical housings andenclosures is to go to non-brominated (non-Br) flame retardant (FR)glass filled resins and International Electrotechnical Commission (IEC)electrical industry norms under preparation aim to limit halogen contentin final electrical and electronic products. However, the addition offillers and flame retardant additives to polycarbonate compositions maynegatively affect impact performance and other mechanical properties.Filler reinforced polycarbonate compositions, also having robustflame-retardant properties, thus present significant technicalchallenges in discovering compositions that can maintain the appropriatebalance of flow, thin wall flame retardancy, and impact strength.Conventional non-bromine FR glass filled polycarbonates include LEXAN™505RU, however the grade may have a lower impact and flame performancethan its bromine-containing counterpart LEXAN™ 503R. The compositions ofthe present disclosure provide bromine and chlorine free, glass filledpolycarbonate compositions exhibiting similar impact performance and arobust flame performance for thin-walled applications when compared to abrominated flame retardant PC contemporary. The use of certain additivesand glass fiber filler with non-brominated flame retardant additivesprovided improved impact strength and maintained flame retardantperformance.

Polycarbonate Polymer

In an aspect, the disclosed compositions may comprise a polycarbonatepolymer component comprising one or more polycarbonate polymers. As usedherein, the term “polycarbonate” includes homopolycarbonates andcopolycarbonates have repeating structural carbonate units. In oneaspect, a polycarbonate can comprise any polycarbonate material ormixture of materials, for example, as recited in U.S. Pat. No.7,786,246, which is hereby incorporated in its entirety for the specificpurpose of disclosing various polycarbonate compositions and methods.

The terms “polycarbonate” or “polycarbonates” as used herein includecopolycarbonates, homopolycarbonates, (co)polyester carbonates andcombinations thereof.

In various aspects, the polycarbonate may comprise copolymers comprisingtwo or more distinct carbonate units. For example, a polycarbonatecopolymer may comprise repeating carbonate units derived from bisphenolacetophenone (BisAP) and a second, chemically distinct dihydroxy monomersuch as a bisphenol, e.g. bisphenol A. Alternatively, a polycarbonatecopolymer can comprise repeating carbonate units derived from (N-PhenylPhenolphthalein) PPPBP and a second, chemically distinct dihydroxymonomer such as a bisphenol, e.g. bisphenol A.

In one aspect, the polycarbonate can comprises aromatic carbonate chainunits and includes compositions having structural units of the formula(I):

in which the R¹ groups are aromatic, aliphatic or alicyclic radicals.Beneficially, R¹ is an aromatic organic radical and, in an alternativeaspect, a radical of the formula (II):-A¹-Y¹-A²-  (II)wherein each of A¹ and A² is a monocyclic divalent aryl radical and Y¹is a bridging radical having zero, one, or two atoms which separate A¹from A². In an exemplary aspect, one atom separates A¹ from A².Illustrative examples of radicals of this type are —O—, —S—, —S(O)—,—S(O₂)—, —C(O)—, methylene, cyclohexyl-methylene,2-[2,2,1]-bicycloheptylidene, ethylidene, isopropylidene,neopentylidene, cyclohexylidene, cyclopentadecylidene,cyclododecylidene, adamantylidene, or the like. In another aspect, zeroatoms separate A¹ from A², with an illustrative example being bisphenol.The bridging radical Y¹ can be a hydrocarbon group or a saturatedhydrocarbon group such as methylene, cyclohexylidene or isopropylidene.

Polycarbonates can be produced by the interfacial reaction polymerprecursors such as dihydroxy compounds in which only one atom separatesA¹ and A². As used herein, the term “dihydroxy compound” includes, forexample, bisphenol compounds having general formula (III) as follows:

wherein R^(a) and R^(b) each independently represent hydrogen, a halogenatom, or a monovalent hydrocarbon group; p and q are each independentlyintegers from 0 to 4; and X^(a) represents one of the groups of formula(IV):

wherein R^(c) and R^(d) each independently represent a hydrogen atom ora monovalent linear or cyclic hydrocarbon group, and R^(e) is a divalenthydrocarbon group.

Non-limiting examples of the types of bisphenol compounds that can berepresented by formula (IV) can include the bis(hydroxyaryl)alkaneseries such as, 1,1-bis(4-hydroxyphenyl)methane,1,1-bis(4-hydroxyphenyl)ethane, 2,2-bis(4-hydroxyphenyl)propane (orbisphenol-A), 2,2-bis(4-hydroxyphenyl)butane,2,2-bis(4-hydroxyphenyl)octane, 1,1-bis(4-hydroxyphenyl)propane,1,1-bis(4-hydroxyphenyl)n-butane, bis(4-hydroxyphenyl)phenylmethane,2,2-bis(4-hydroxy-1-methylphenyl)propane,1,1-bis(4-hydroxy-t-butylphenyl)propane,2,2-bis(4-hydroxy-3-bromophenyl)propane, or the like;bis(hydroxyaryl)cycloalkane series such as,1,1-bis(4-hydroxyphenyl)cyclopentane,1,1-bis(4-hydroxyphenyl)cyclohexane, or the like, or combinationsincluding at least one of the foregoing bisphenol compounds.

Other bisphenol compounds that can be represented by formula (III)include those where X is —O—, —S—, —SO— or —SO₂—. Some examples of suchbisphenol compounds are bis(hydroxyaryl)ethers such as 4,4′-dihydroxydiphenylether, 4,4′-dihydroxy-3,3′-dimethylphenyl ether, or the like;bis(hydroxy diaryl)sulfides, such as 4,4′-dihydroxy diphenyl sulfide,4,4′-dihydroxy-3,3′-dimethyl diphenyl sulfide, or the like; bis(hydroxydiaryl) sulfoxides, such as, 4,4′-dihydroxy diphenyl sulfoxides,4,4′-dihydroxy-3,3′-dimethyl diphenyl sulfoxides, or the like;bis(hydroxy diaryl)sulfones, such as 4,4′-dihydroxy diphenyl sulfone,4,4′-dihydroxy-3,3′-dimethyl diphenyl sulfone, or the like; orcombinations including at least one of the foregoing bisphenolcompounds.

Other bisphenol compounds that can be utilized in the polycondensationof polycarbonate are represented by the formula (V)

wherein, R^(f), is a halogen atom of a hydrocarbon group having 1 to 10carbon atoms or a halogen substituted hydrocarbon group; n is a valuefrom 0 to 4. When n is at least 2, R^(f) can be the same or different.Examples of bisphenol compounds that can be represented by the formula(IV), are resorcinol, substituted resorcinol compounds such as 3-methylresorcin, 3-ethyl resorcin, 3-propyl resorcin, 3-butyl resorcin,3-t-butyl resorcin, 3-phenyl resorcin, 3-cumyl resorcin,2,3,4,6-tetrafluoro resorcin, 2,3,4,6-tetrabromo resorcin, or the like;catechol, hydroquinone, substituted hydroquinones, such as 3-methylhydroquinone, 3-ethyl hydroquinone, 3-propyl hydroquinone, 3-butylhydroquinone, 3-t-butyl hydroquinone, 3-phenyl hydroquinone, 3-cumylhydroquinone, 2,3,5,6-tetramethyl hydroquinone, 2,3,5,6-tetra-t-butylhydroquinone, 2,3,5,6-tetrafluoro hydroquinone, 2,3,5,6-tetrabromohydroquinone, or the like; or combinations including at least one of theforegoing bisphenol compounds.

In one aspect, the bisphenol compound is bisphenol A. In an exemplaryaspect, the polycarbonate polymer component comprises a bisphenol Apolycarbonate polymer. In another exemplary aspect, the polycarbonatecomponent comprises a blend of at least two different grade bisphenol Apolycarbonates. To that end, a polycarbonate grade may, for example, becharacterized by the melt volume rate (MVR) of the polycarbonate. Forexample, a disclosed polycarbonate, such as a bisphenol A polycarbonate,may be characterized by exhibiting a melt Volume Rate (MVR) in the rangeof from 4 gram per 10 minutes (g/10 min) to 30 g/10 min at 300° C./1.2kg. For example, the MVR can range from 10 g/10 min to 25 g/10 min,including for example a MVR in the range of from 15 g/10 min to 20 g/10min. Further, for example, the MVR can be in the range of from 4 g/10min or 30 g/10 min.

Polycarbonates may include linear bisphenol-A polycarbonates produced bymelt polymerization. The melt polycarbonate process is based oncontinuous reaction of a dihydroxy compound and a carbonate source in amolten stage. For example, the polycarbonate polymer may be linearbisphenol-A polycarbonates produced by melt polymerization. The meltpolycarbonate process is based on continuous reaction of a dihydroxycompound and a carbonate source in a molten stage. A melt polycarbonatein some aspects may have a molecular weight (Mw) of about 15,000 toabout 120,000 Dalton on a polystyrene basis. The melt polycarbonateproduct may have an endcap level of about 45% to about 80%. Somepolycarbonates have an endcap level of about 45% to about 75%, about 55%to about 75%, about 60% to about 70% or about 60% to about 65%. Certainpolycarbonates have at least 200 parts per million (ppm) of hydroxidegroups. Certain polycarbonates have 200-1100 ppm or 950 to 1050 ppmhydroxide groups.

The polycarbonate polymer may contain endcapping agents. Any suitableendcapping agents can be used provided that such agents do notsignificantly adversely impact the desired properties of thepolycarbonate composition (transparency, for example). Endcapping agentsinclude mono-phenolic compounds, mono-carboxylic acid chlorides, and/ormono-chloroformates. Mono-phenolic endcapping agents are exemplified bymonocyclic phenols such as phenol and C₁-C₂₂ alkyl-substituted phenolssuch as p-cumyl-phenol, resorcinol monobenzoate, and p- andtertiary-butyl phenol; and monoethers of diphenols, such asp-methoxyphenol.

Additionally, some polycarbonates include from about 200 to about 2000ppm, or from about 250 parts per million (ppm) to about 1800 ppm Friesproducts. Fries products include ester type of structures A, B, and C.

Apart from the main polymerization reaction in polycarbonate production,there is a series of side reactions consisting of chain rearrangementsof the polymer backbone that lead to branching that are often referredto as Fries rearrangement. The Fries species specifically found inbisphenol A melt polycarbonates include the ester type of structures A,B, and C.

Linear Fries:

Branched Fries:

Acid Fries:

The Fries reaction is induced by the combined effect of basic catalysts,temperature, and residence time, which generally result in melt-producedpolycarbonates being branched as compared with the interfacialpolycarbonates since their manufacturing temperatures are lower. Becausehigh branching levels in the resin can have a negative effect on themechanical properties of the polycarbonate (for example, on impactstrength), a product with lower branched Fries product may be desirable.

In certain embodiments, polycarbonate produced by interfacialpolymerization may be utilized. In some processes, bisphenol A andphosgene are reacted in an interfacial polymerization process.Typically, the disodium salt of bisphenol A is dissolved in water andreacted with phosgene which is typically dissolved in a solvent that notmiscible with water (such as a chlorinated organic solvent likemethylene chloride).

In some embodiments, the polycarbonate comprises interfacialpolycarbonate having a weight average molecular weight of from about10,000 grams per mole (g/mol) to about 50,000 g/mol preferably about15,000 g/mol to about 45,000 g/mol. Some interfacial polycarbonates havean endcap level of at least 90% or preferably 95%.

In at least one aspect, the composition may include a first and secondpolycarbonate as the polycarbonate polymer component. In a furtheraspect, the polycarbonate polymer may comprise at least one bisphenol-Apolycarbonate polymer. Non-limiting examples of the polycarbonate mayinclude homopolymers LEXAN™ 105 and/or LEXAN™ 175, both available fromSABIC™. In some compositions, the polycarbonate polymer comprises atleast one polycarbonate polymer having a molecular weight (Mw) of lessthan 25,000 g/mol, for example about 21,800 g/mol, and a secondpolycarbonate polymer have a molecular weight (Mw) of at least 28,000g/mol, for example 30,000 g/mol. In some compositions, the molar ratioof said first polycarbonate polymer to said second polycarbonate polymeris from about 7:1 to about 4:1.

Polycarbonates” and “polycarbonate polymers” as used herein can furtherinclude blends of polycarbonates with other copolymers comprisingcarbonate chain units. An exemplary copolymer is a polyester carbonate,also known as a copolyester-polycarbonate. Such copolymers furthercontain, in addition to recurring carbonate chain units, repeating unitsof formula (VI)

wherein D is a divalent radical derived from a dihydroxy compound, andmay be, for example, a C₂₋₁₀ alkylene radical, a C₆₋₂₀ alicyclicradical, a C₆₋₂₀ aromatic radical or a polyoxyalkylene radical in whichthe alkylene groups contain 2 to about 6 carbon atoms, specifically 2,3, or 4 carbon atoms; and T is a divalent radical derived from adicarboxylic acid, and may be, for example, a C₂₋₁₀ alkylene radical, aC₆₋₂₀ alicyclic radical, a C₆₋₂₀ alkyl aromatic radical, or a C₆₋₂₀aromatic radical.

In one aspect, D is a C₂₋₆ alkylene radical. In another aspect, D isderived from an aromatic dihydroxy compound of formula (VII):

wherein each R^(h) is independently a halogen atom, a C₁₋₁₀ hydrocarbongroup, or a C₁₋₁₀ halogen substituted hydrocarbon group, and n is 0 to4. The halogen is usually bromine. Examples of compounds that may berepresented by the formula (VIII) include resorcinol, substitutedresorcinol compounds such as 5-methyl resorcinol, 5-ethyl resorcinol,5-propyl resorcinol, 5-butyl resorcinol, 5-t-butyl resorcinol, 5-phenylresorcinol, 5-cumyl resorcinol, 2,4,5,6-tetrafluoro resorcinol,2,4,5,6-tetrabromo resorcinol, or the like; catechol; hydroquinone;substituted hydroquinones such as 2-methyl hydroquinone, 2-ethylhydroquinone, 2-propylhydroquinone, 2-butyl hydroquinone, 2-t-butylhydroquinone, 2-phenyl hydroquinone, 2-cumyl hydroquinone,2,3,5,6-tetramethyl hydroquinone, 2,3,5,6-tetra-t-butyl hydroquinone,2,3,5,6-tetrafluoro hydroquinone, 2,3,5,6-tetrabromo hydroquinone, orthe like; or combinations comprising at least one of the foregoingcompounds.

Examples of aromatic dicarboxylic acids that can be used to prepare thepolyesters include isophthalic or terephthalic acid,1,2-di(p-carboxyphenyl)ethane, 4,4′-dicarboxydiphenyl ether,4,4′-bisbenzoic acid, and mixtures comprising at least one of theforegoing acids. Acids containing fused rings can also be present, suchas in 1,4-, 1,5-, or 2,6-naphthalenedicarboxylic acids. Specificdicarboxylic acids are terephthalic acid, isophthalic acid, naphthalenedicarboxylic acid, cyclohexane dicarboxylic acid, or mixtures thereof. Aspecific dicarboxylic acid comprises a mixture of isophthalic acid andterephthalic acid wherein the weight ratio of terephthalic acid toisophthalic acid is about 10:1 to about 0.2:9.8. In another specificaspect, D is a C₂₋₆ alkylene radical and T is p-phenylene, m-phenylene,naphthalene, a divalent cycloaliphatic radical, or a mixture thereof.This class of polyester includes the poly(alkylene terephthalates).

In other aspects, poly(alkylene terephthalates) can be used. Specificexamples of suitable poly(alkylene terephthalates) are poly(ethyleneterephthalate) (PET), poly(1,4-butylene terephthalate) (PBT),poly(ethylene naphthanoate) (PEN), poly(butylene naphthanoate),polybutylene naphthalate (PBN), (polypropylene terephthalate) (PPT),polycyclohexanedimethanol terephthalate (PCT), and combinationscomprising at least one of the foregoing polyesters. Also contemplatedare the above polyesters with a minor amount, e.g., from about 0.5 toabout 10 percent by weight, of units derived from an aliphatic diacidand/or an aliphatic polyol to make copolyesters.

Copolymers comprising alkylene terephthalate repeating ester units withother ester groups can also be useful. Useful ester units can includedifferent alkylene terephthalate units, which can be present in thepolymer chain as individual units, or as blocks of poly(alkyleneterephthalates). Specific examples of such copolymers include poly(cyclohexanedimethylene terephthalate)-co-poly(ethylene terephthalate),abbreviated as PETG where the polymer comprises greater than or equal to50 mol % of poly(ethylene terephthalate), and abbreviated as PCTG wherethe polymer comprises greater than 50 mol % ofpoly(1,4-cyclohexanedimethylene terephthalate).

Poly(cycloalkylene diester)s can also include poly(alkylenecyclohexanedicarboxylate)s. Of these, a specific example ispoly(1,4-cyclohexanedimethanol-1,4-cyclohexanedicarboxylate) (PCCD),having recurring units of formula (IX):

wherein, as described using formula (VIII), D is a1,4-cyclohexanedimethylene group derived from 1,4-cyclohexanedimethanol,and T is a cyclohexane ring derived from cyclohexanedicarboxylate or achemical equivalent thereof, and may comprise the cis-isomer, thetrans-isomer, or a combination comprising at least one of the foregoingisomers.

The polycarbonate polymer component can also comprise apolycarbonate-polysiloxane copolymer. As used herein, the term“polycarbonate-polysiloxane copolymer” is equivalent topolysiloxane-polycarbonate copolymer, polycarbonate-polysiloxanepolymer, or polysiloxane-polycarbonate polymer. In various aspects, thepolycarbonate-polysiloxane copolymer can be a block copolymer comprisingone or more polycarbonate blocks and one or more polysiloxane blocks.The polysiloxane-polycarbonate copolymer comprises polydiorganosiloxaneblocks comprising structural units of the general formula IX) below:

wherein the polydiorganosiloxane block length (E) is from about 20 toabout 60; wherein each R group can be the same or different, and isselected from a C₁₋₁₃ monovalent organic group; wherein each M can bethe same or different, and is selected from a halogen, cyano, nitro,C₁-C₈ alkylthio, C₁-C₈ alkyl, C₁-C₈ alkoxy, C₂-C₈ alkenyl, C₂-C₈alkenyloxy group, C₃-C₈ cycloalkyl, C₃-C₈ cycloalkoxy, C₆-C₁₀ aryl,C₆-C₁₀ aryloxy, C₇-C₁₂ aralkyl, C₇-C₁₂ aralkoxy, C₇-C₁₂ alkylaryl, orC₇-C₁₂ alkylaryloxy, and where each n is independently 0, 1, 2, 3, or 4.The polysiloxane-polycarbonate copolymer also comprises polycarbonateblocks comprising structural units of the general formula (X) below:

wherein at least 60 percent of the total number of R¹ groups comprisearomatic moieties and the balance thereof comprise aliphatic, alicyclic,or aromatic moieties. Polysiloxane-polycarbonates materials includematerials disclosed and described in U.S. Pat. No. 7,786,246, which ishereby incorporated by reference in its entirety for the specificpurpose of disclosing various compositions and methods for manufactureof same. Non-limiting examples of polysiloxane-polycarbonate copolymerscan comprise various copolymers available from SABIC™ Innovativeplastics.

In various aspects, the polycarbonate polymer component is present in anamount from about 60 wt. % to about 98 wt. % of the total weight of thecomposition. In a still further aspect, the polycarbonate polymer ispresent in an amount from about 40 wt. % to about 90 wt %. In a yetfurther aspect, the polycarbonate polymer is present in an amount fromabout 70 wt. % to about 85 wt. %, or from about 50 wt. % to about 90 wt.%, or from about 60 wt. % to about 90 wt. %, or from about 65 wt. % toabout 90 wt. %, or from about 67 wt. % to about 90 wt. %, or from about69 wt. % to about 90 wt. %, or from about 70 wt. % to about 89 wt. %, orfrom about 70 wt. % to about 88 wt. %, or from about 70 wt. % to about88 wt. %, or from about 70 wt. % to about 85 wt. %, or from about 70 wt.% to about 80 wt. %, or from about 40 wt. % to about 95 wt. %, or fromabout 50 wt. % to about 95 wt. %, or from about 55 wt. % to about 95 wt.%, or from about 60 wt. % to about 95 wt. %, or from about 65 wt. % toabout 95 wt. %, or from about 70 wt. % to about 95 wt. %, or from about75 wt. % to about 95 wt. %, or from about 77 wt. % to about 95 wt. %. Asan example, the polycarbonate polymer is present an amount about 50 wt.%. In a yet further aspect, the polycarbonate polymer is present in anamount of about 60 wt. %. In an even further aspect, the polycarbonatepolymer is present in an amount of about 70 wt. %.

Glass Fiber

According to aspects of the present disclosure, the disclosedcompositions may comprise a non-bonding glass fiber. In some examples, anon-bonding glass fiber included as a fiber filler in the presentdisclosure may provide a composition having a higher impact strengththan a substantially similar composition comprising a bonding glassfiber. Substantially similar composition may refer to a compositioncomprising the same components but for a specified component. However,while a non-bonding glass fiber may improve impact strength propertiesin some of the non-brominated and non-chlorinated flame retardantformulations evaluated herein, the robustness of flame performance forthin-walled applications (less than 1.5 mm or less than 0.8 mm) may bepoorer. A combination of the non-bonding glass fiber filler with certainstabilizer additives in the polycarbonate composition may improve bothimpact strength and maintain flame performance.

A non-bonding glass fiber, also characterized as a non-binding glassfiber, may refer to a glass fiber filler that does not provide specificadhesion to a polymer resin to which it is added. That is, individualfibers of the glass fiber filler may not demonstrate an affinity towardsthe polymer matrix. Comparatively, bonding glass fiber provides specificadhesion with the specific polymer resin to which it is added. A bondingglass fiber filler may exhibit affinity toward the polycarbonate resinmatrix. This affinity may be attributed to the glass sizing, among anumber of other forces.

In one aspect, the disclosed compositions comprise a non-bonding glassfiber selected from E-glass, S-glass, AR-glass, T-glass, D-glass andR-glass. In a still further aspect, the non-bonding glass fiber may beselected from E-glass, S-glass, and combinations thereof. In oneexample, the non-bonding glass fiber is an E-glass or EC glass type.

The non-bonding glass fibers can be made by standard processes, e.g., bysteam or air blowing, flame blowing, and mechanical pulling. Exemplaryglass fibers for polycarbonate reinforcement are made by mechanicalpulling.

The non-bonding glass fibers may be sized or unsized. Sized glass fibersare coated on their surfaces with a sizing composition selected forcompatibility with the polycarbonate. The sizing composition facilitateswet-out and wet-through of the polycarbonate upon the fiber strands andassists in attaining desired physical properties in the polycarbonatecomposition. In various further aspects, the non-bonding glass fiber issized with a coating agent. In a further aspect, the coating agent ispresent in an amount from about 0.1 wt % to about 5 wt % based on theweight of the glass fibers. In a still further aspect, the coating agentis present in an amount from about 0.1 wt % to about 2 wt % based on theweight of the glass fibers.

In preparing the glass fibers, a number of filaments can be formedsimultaneously, sized with the coating agent and then bundled into whatis called a strand. Alternatively the strand itself may be first formedof filaments and then sized. The amount of sizing employed is generallythat amount which is sufficient to bind the glass filaments into acontinuous strand and ranges from about 0.1 to about 5 wt %, about 0.1to 2 wt % based on the weight of the glass fibers. Generally, this maybe about 1.0 wt % based on the weight of the glass filament.

In a further aspect, the non-bonding glass fiber may be continuous orchopped. In some examples, the glass fiber is chopped. Glass fibers inthe form of chopped strands may have a length of about 0.3 millimeter toabout 10 centimeters, specifically about 0.5 millimeter to about 5centimeters, and more specifically about 1.0 millimeter to about 2.5centimeters. In various further aspects, the glass fiber has a lengthfrom about 0.2 mm to about 20 mm. In a yet further aspect, the glassfiber has a length from about 0.2 mm to about 10 mm. In an even furtheraspect, the glass fiber has a length from about 0.7 mm to about 7 mm. Inthis area, where a thermoplastic resin is reinforced with glass fibersin a composite form, fibers having a length of about 0.4 mm aregenerally referred to as long fibers, and shorter ones are referred toas short fibers. In a still further aspect, the glass fiber can have alength of 1 mm or longer. In yet a further aspect, the glass fiber canhave a length of 2 mm or longer.

The non-bonding glass fiber component may be present in an amount fromabout greater than 0 wt % to about 20 wt %. In some examples, thenon-bonding glass fiber may be present in an amount from greater thanabout 5 wt % to about 15 wt %. In a yet further aspect, the non-bondingglass fiber component may be present in an amount from greater thanabout 5 wt % to about 10 wt %. The disclosed thermoplastic compositionmay comprise from about 2 wt. % to about 20 wt. % of non-bonding glassfiber filler. For example, the glass fiber can be present in an amountof about 10 wt. %. In a still further aspect, the non-bonding glassfiber component may be present in an amount from greater than about 3wt. % to about 10 wt. % or from about 3 wt. % to about 8 wt. %.

The non-bonding glass fiber may have a round (or circular), flat, orirregular cross-section. Thus, use of non-round fiber cross sections ispossible. However, in some examples, the non-bonding glass fiber mayhave a circular cross-section. The width or diameter of the non-bondingglass fiber may be from about 1 micrometer (μm) to about 20 μm, or fromabout 5 to about 20 μm. In a further example, the width or diameter ofthe glass fiber may be from about 5 to about 15 μm. In certaincompositions, the non-bonding glass fiber may have a width or diameterof about 14 μm.

Flame Retardant

In certain aspects of the present disclosure, the thermoplasticcompositions can comprise a flame retardant additive. The flameretardant additive may comprise a flame retardant material or mixture offlame retardant materials suitable for use in the disclosedpolycarbonate compositions. In an example, the flame retardant additivem comprise a phosphate containing material.

In various aspects, the flame retardant additive may be free of orsubstantially free of bromine or chlorine. Free of, or substantiallyfree of, may refer to less than about 1 wt. % or more specifically, lessthan about 0.1 wt. % present in the total weight of a composition. Incertain examples, the polycarbonate is substantially free of bromine orchlorine atoms. In further examples, the flame retardant additive issubstantially free of bromine or chlorine atoms. By “substantially free”it is intended that less than about 1 wt. %, or less than about 0.1 wt.%, of the polycarbonate composition comprises bromine and/or chlorineatoms.

Non-bromine/non-chlorine phosphorus-containing flame retardants mayinclude, for example, organic phosphates and organic compoundscontaining phosphorus-nitrogen bonds. The flame retardant optionally isa non-bromine or non-chlorine based metal salt, e.g., of a monomeric orpolymeric aromatic sulfonate or mixture thereof. The metal salt is, forexample, an alkali metal or alkali earth metal salt or mixed metal salt.The metals of these groups include sodium, lithium, potassium, rubidium,cesium, beryllium, magnesium, calcium, strontium, francium and barium.Examples of flame retardants include cesium benzenesulfonate and cesiump-toluenesulfonate.

The flame retardant additive may comprise an oligomer organophosphorusflame retardant, including for example, bisphenol A diphenyl phosphate(BPADP). In a further example, the flame retardant can be selected fromoligomeric phosphate, polymeric phosphate, oligomeric phosphonate,ammonium polyphosphate (Exolit™ OP) or mixed phosphate/phosphonate esterflame retardant compositions. The flame retardant can be selected fromtriphenyl phosphate; cresyldiphenylphosphate;tri(isopropylphenyl)phosphate; resorcinol bis(diphenylphosphate); andbisphenol-A bis(diphenyl phosphate). In an aspect, the flame retardantcan comprise bisphenol A bis(diphenyl phosphate) (BPDAP).

In some examples, the flame retardant additives may include, forexample, flame retardant salts such as alkali metal salts ofperfluorinated C1-C16 alkyl sulfonates such as potassium perfluorobutanesulfonate (Rimar salt), potassium perfluoroctane sulfonate,tetraethylammonium perfluorohexane sulfonate, potassium diphenylsulfonesulfonate (KSS), and the like, sodium benzene sulfonate, sodium toluenesulfonate (NATS) and the like; and salts formed by reacting for examplean alkali metal or alkaline earth metal (for example lithium, sodium,potassium, magnesium, calcium and barium salts) and an inorganic acidcomplex salt, for example, an oxo-anion, such as alkali metal andalkaline-earth metal salts of carbonic acid, such as sodium carbonateNa₂CO₃, potassium carbonate K₂CO₃, magnesium carbonate MgCO₃, calciumcarbonate CaCO₃, and barium carbonate BaCO₃ or fluoro-anion complex suchas trilithium aluminum hexafluoride Li₃AlF₆, barium silicon fluorideBaSiF₆, potassium tetrafluoroborate KBF₄, tripotassium aluminumhexafluoride K₃AlF₆, potassium aluminum fluoride KAlF₄, potassiumsilicofluoride K₂SiF₆, and/or sodium aluminum hexafluoride Na₃AlF₆ orthe like. Rimar salt and KSS and NATS (sodium toluene sulfonic acid),alone or in combination with other flame retardants, are particularlyuseful in the compositions disclosed herein.

Metal synergists, e.g., antimony oxide, may also be used with the flameretardant additive. A flame retardant can be present in amounts of 1 to25 parts by weight, more specifically 2 to 20 parts by weight, based on100 parts by weight of the total composition, excluding any filler.

The flame retardant may be present in an amount of from about 0.01 wt. %to about 1 wt. % based on the total weight of the composition. Forexample, the flame retardant may be present in an amount of from about0.05 wt. % to about 0.5 wt. %, or from about 0.05 wt. % to about 0.25wt. % based on the total weight of the composition.

Additives

According to aspects of the present disclosure, the disclosedcompositions may comprise a non-bonding glass fiber. The impact strengthof the flame retardant, glass fiber filled polycarbonate polymers maydepend upon the type of glass fiber used. While a non-bonding glassfiber may improve impact strength properties in some of thenon-brominated and/or non-chlorinated flame retardant formulationsevaluated herein, the robustness of flame performance for thin-walledapplications (less than 1.5 mm or less than 0.8 mm) was reduced.Combining the non-bonding glass fiber filler with a certain additivemixture both improved impact strength and maintained flame performance.

The disclosed additive mixture may comprise an acid stabilizer and aphosphorous-based heat stabilizer or the disclosed additive mixture maycomprise a plurality of phosphorous-based heat stabilizers. Acombination of an acid stabilizer and a phosphorous-based heatstabilizer with the non-bonding glass fibers has been shown to bothimprove multi-axial impact strength and maintain thin-walled flameretardancy.

In some aspects, the additive may comprise a heat stabilizer additive.In some aspects the heat stabilizer component includes at least oneorganophosphorus compound, including but not limited to a phosphite,phosphine or phosphonite compound. In particular aspects, the heatstabilizer component includes tris-(2,4-di-tert-butylphenyl) phosphite(e.g., Irgafos™ 168, available from BASF) (IRG), triphenylphosphine(TPP), tridecylphosphite (TDP),tetrakis(2,4-di-tert-butylphenyl)-4,4-diphenyldiphosphonite) (PEPQ), bis(2,4-dicumylphenyl) pentaerythritol diphosphite (e.g., Doverphos™S-9228, available from Dover Chemical) (DP), diphenyl monodecylphosphite (DPDP), or combinations thereof.

In an example, the disclosed composition may comprisetetrakis(2,4-di-tert-butylphenyl)-4,4-diphenyldiphosphonite as aphosphorous based stabilizer as provided above.Tetrakis(2,4-di-tert-butylphenyl)-4,4-diphenyldiphosphonite) iscommercially available as phosphonite PEPQ and may be represented by thefollowing structural formula. PEPQ is a diphenolic phosphonite.

In a specific example, the disclosed composition may comprise adiphenolic diphosphate such as bis (2,4-dicumylphenyl) pentaerythritoldiphosphite as a phosphorous based stabilizer as provided above. Bis(2,4-dicumylphenyl) pentaerythritol diphosphiteis commercially availableas Doverphos™ S-9228 and may be represented by the following structuralformula.

In some aspects the phosphorous based stabilizer component is present inthe molded article in an amount of from about 0.01 to about 0.2 wt % ofthe composition, or in certain aspects in an amount of from about 0.01to about 0.08 wt % of the composition.

An acid stabilizer component in some aspects may be present in thedisclosed composition. In certain aspects the acid stabilizer componentcomprises a sulfonic acid ester. Other acid stabilizer additives mayinclude organophosphorus compounds, including but not limited tophosphorous acid, phosphoric acid, or a combination thereof. Inparticular aspects, butyl tosylate (e.g., butyl p-toluenesulfonate, orBuTos) may be present in the disclosed compositions. As an example,BuTos may be used as a component of a polymer masterbatch, where thepolymer masterbatch comprises about 0.3 wt. % of BuTos using 14 wt. %pentaerythritol tetrastearate. In certain examples of the presentdisclosure, a sulfonic acid ester such as butyl tosylate may provide apolycarbonate composition exhibiting better physical and mechanicalproperties (e.g., FR and multi-axial impact (MAI)) than a polycarbonatecomposition comprising a phosphorous acid as the acid stabilizer. Insome aspects the acid stabilizer component is present in the moldedarticle in an amount of from about 0.001 wt. % to about 5 wt. % in thecomposition, or in certain aspects in an amount of from about 0.001 wt.% to about 1 wt. % in the composition, or in yet further aspects in anamount from about 0.001 to about 0.05 wt. %.

In a specific example, butyl tosylate as an acid stabilizer andtris-(2,4-di-tert-butylphenyl) phosphite a heat stabilizer have beencombined with non-bonding glass fiber and a non-bromine/non-chlorine FR(Rimar salt) to provide a polycarbonate composition exhibiting improvedmultiaxial impact strength and robust flame retardant performance. Thesedisclosed compositions exhibited better flame retardant FR and MAIproperties than a substantially similar polycarbonate composition havinga bonding glass fiber and/or in the absence of butyl tosylate ormultiple phosphorous-based heat stabilizers.

The disclosed polycarbonate composition may comprise one or moreadditional additives conventionally used in the manufacture of moldedthermoplastic parts with the proviso that the optional additives do notadversely affect the desired properties of the resulting composition.Mixtures of optional additives can also be used. Such additives can bemixed at a suitable time during the mixing of the components for formingthe composite mixture. For example, the disclosed composition cancomprise one or more additional fillers, plasticizers, stabilizers,anti-static agents, impact modifiers, colorant, antioxidant, and/or moldrelease agents. In one aspect, the composition can further comprises oneor more additives selected from an antioxidant, a mold release agent,and stabilizer.

The composition disclosed herein can comprise one or more fillers. Thefiller can be selected to impart additional impact strength and/orprovide additional characteristics that can be based on the finalselected characteristics of the polymer composition. In some aspects,the filler(s) can comprise inorganic materials which can include clay,titanium oxide, asbestos fibers, silicates and silica powders, boronpowders, calcium carbonates, talc, kaolin, sulfides, barium compounds,metals and metal oxides, wollastonite, glass spheres, glass fibers,flaked fillers, fibrous fillers, natural fillers and reinforcements, andreinforcing organic fibrous fillers.

Appropriate fillers or reinforcing agents can include, for example,mica, clay, feldspar, quartz, quartzite, perlite, tripoli, diatomaceousearth, aluminum silicate (mullite), synthetic calcium silicate, fusedsilica, fumed silica, sand, boron-nitride powder, boron-silicate powder,calcium sulfate, calcium carbonates (such as chalk, limestone, marble,and synthetic precipitated calcium carbonates) talc (including fibrous,modular, needle shaped, and lamellar talc), wollastonite, hollow orsolid glass spheres, silicate spheres, cenospheres, aluminosilicate or(armospheres), kaolin, whiskers of silicon carbide, alumina, boroncarbide, iron, nickel, or copper, continuous and chopped carbon fibersor glass fibers, molybdenum sulfide, zinc sulfide, barium titanate,barium ferrite, barium sulfate, heavy spar, TiO₂, aluminum oxide,magnesium oxide, particulate or fibrous aluminum, bronze, zinc, copper,or nickel, glass flakes, flaked silicon carbide, flaked aluminumdiboride, flaked aluminum, steel flakes, natural fillers such as woodflour, fibrous cellulose, cotton, sisal, jute, starch, lignin, groundnut shells, or rice grain husks, reinforcing organic fibrous fillerssuch as poly(ether ketone), polyimide, polybenzoxazole, poly(phenylenesulfide), polyesters, polyethylene, aromatic polyamides, aromaticpolyimides, polyetherimides, polytetrafluoroethylene, and poly(vinylalcohol), as well combinations comprising at least one of the foregoingfillers or reinforcing agents. The fillers and reinforcing agents can becoated with a layer of metallic material to facilitate conductivity, orsurface treated with silanes to improve adhesion and dispersion with thepolymer matrix. Fillers generally can be used in amounts of 1 to 200parts by weight, based on 100 parts by weight of based on 100 parts byweight of the total composition. In various aspects, the filler cancomprise talc. For example, the thermoplastic composition can comprisefine talc as a filler. The talc filler can have an average diameter offrom about 0.1 microns (micrometers, μm) to about 4.0 μm.

The thermoplastic composition can comprise an antioxidant. Theantioxidants can include either a primary or a secondary antioxidant.For example, antioxidants can include organophosphites such astris(nonyl phenyl)phosphite, tris(2,4-di-t-butylphenyl)phosphite,bis(2,4-di-t-butylphenyl)pentaerythritol diphosphite, distearylpentaerythritol diphosphite or the like; alkylated monophenols orpolyphenols; alkylated reaction products of polyphenols with dienes,such astetrakis[methylene(3,5-di-tert-butyl-4-hydroxyhydrocinnamate)]methane,or the like; butylated reaction products of para-cresol ordicyclopentadiene; alkylated hydroquinones; hydroxylated thiodiphenylethers; alkylidene-bisphenols; benzyl compounds; esters ofbeta-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionic acid with monohydricor polyhydric alcohols; esters ofbeta-(5-tert-butyl-4-hydroxy-3-methylphenyl)-propionic acid withmonohydric or polyhydric alcohols; esters of thioalkyl or thioarylcompounds such as distearylthiopropionate, dilaurylthiopropionate,ditridecylthiodipropionate,octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate,pentaerythrityl-tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionateor the like; amides ofbeta-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionic acid or the like, orcombinations including at least one of the foregoing antioxidants.Antioxidants can generally be used in amounts of from 0.01 to 0.5 partsby weight, based on 100 parts by weight of the total composition,excluding any filler.

In various aspects, the thermoplastic composition can comprise a moldrelease agent. Exemplary mold releasing agents can include for example,metal stearate, stearyl stearate, pentaerythritol tetrastearate,beeswax, montan wax, paraffin wax, or the like, or combinationsincluding at least one of the foregoing mold release agents. Moldreleasing agents are generally used in amounts of from about 0.1 toabout 1.0 parts by weight, based on 100 parts by weight of the totalcomposition, excluding any filler.

In an aspect, the thermoplastic composition can comprise a heatstabilizer. As an example, heat stabilizers can include, for example,organo phosphites such as triphenyl phosphite,tris-(2,6-dimethylphenyl)phosphite, tris-(mixed mono- anddi-nonylphenyl)phosphite or the like; phosphonates such asdimethylbenzene phosphonate or the like, phosphates such as trimethylphosphate, or the like, or combinations including at least one of theforegoing heat stabilizers. Heat stabilizers can generally be used inamounts of from 0.01 to 0.5 parts by weight based on 100 parts by weightof the total composition, excluding any filler.

In further aspects, light stabilizers can be present in thethermoplastic composition. Exemplary light stabilizers can include, forexample, benzotriazoles such as2-(2-hydroxy-5-methylphenyl)benzotriazole,2-(2-hydroxy-5-tert-octylphenyl)-benzotriazole and 2-hydroxy-4-n-octoxybenzophenone or the like or combinations including at least one of theforegoing light stabilizers. Light stabilizers can generally be used inamounts of from about 0.1 to about 1.0 parts by weight, based on 100parts by weight of the total composition, excluding any filler.

The thermoplastic composition can also comprise plasticizers. Forexample, plasticizers can include phthalic acid esters such asdioctyl-4,5-epoxy-hexahydrophthalate, tris-(octoxycarbonylethyl)isocyanurate, tristearin, epoxidized soybean oil or the like, orcombinations including at least one of the foregoing plasticizers.Plasticizers are generally used in amounts of from about 0.5 to about3.0 parts by weight, based on 100 parts by weight of the totalcomposition, excluding any filler.

In further aspects, the disclosed composition can comprise antistaticagents. These antistatic agents can include, for example, glycerolmonostearate, sodium stearyl sulfonate, sodium dodecylbenzenesulfonateor the like, or combinations of the foregoing antistatic agents. In oneaspect, carbon fibers, carbon nanofibers, carbon nanotubes, carbonblack, or any combination of the foregoing can be used in a polymericresin containing chemical antistatic agents to render the compositionelectrostatically dissipative.

Ultraviolet (UV) absorbers can also be present in the disclosedthermoplastic composition. Exemplary ultraviolet absorbers can includefor example, hydroxybenzophenones; hydroxybenzotriazoles;hydroxybenzotriazines; cyanoacrylates; oxanilides; benzoxazinones;2-(2H-benzotriazol-2-yl)-4-(1,1,3,3-tetramethylbutyl)-phenol (CYASORB™5411); 2-hydroxy-4-n-octyloxybenzophenone (CYASORB™ 531);2-[4,6-bis(2,4-dimethylphenyl)-1,3,5-triazin-2-yl]-5-(octyloxy)-phenol(CYASORB™ 1164); 2,2′-(1,4-phenylene)bis(4H-3,1-benzoxazin-4-one)(CYASORB™ UV-3638);1,3-bis[(2-cyano-3,3-diphenylacryloyl)oxy]-2,2-bis[[(2-cyano-3,3-diphenylacryloyl)oxy]methyl]propane(UVINUL™ 3030); 2,2′-(1,4-phenylene)bis(4H-3,1-benzoxazin-4-one);1,3-bis[(2-cyano-3,3-diphenylacryloyl)oxy]-2,2-bis[[(2-cyano-3,3-diphenylacryloyl)oxy]methyl]propane;nano-size inorganic materials such as titanium oxide, cerium oxide, andzinc oxide, all with particle size less than 100 nanometers; or thelike, or combinations including at least one of the foregoing UVabsorbers. UV absorbers are generally used in amounts of from 0.01 to3.0 parts by weight, based on 100 parts by weight of the totalcomposition, excluding any filler.

The thermoplastic composition can further comprise a lubricant. As anexample, lubricants can include for example, fatty acid esters such asalkyl stearyl esters, e.g., methyl stearate or the like; mixtures ofmethyl stearate and hydrophilic and hydrophobic surfactants includingpolyethylene glycol polymers, polypropylene glycol polymers, andcopolymers thereof e.g., methyl stearate and polyethylene-polypropyleneglycol copolymers in a suitable solvent; or combinations including atleast one of the foregoing lubricants. Lubricants can generally be usedin amounts of from about 0.1 to about 5 parts by weight, based on 100parts by weight of the total composition, excluding any filler.

Anti-drip agents can also be used in the composition, for example afibril forming or non-fibril forming fluoropolymer such aspolytetrafluoroethylene (PTFE). The anti-drip agent can be encapsulatedby a rigid copolymer, for example styrene-acrylonitrile copolymer (SAN).PTFE encapsulated in SAN is known as TSAN. In one example, TSAN cancomprise 50 wt. % PTFE and 50 wt. % SAN, based on the total weight ofthe encapsulated fluoropolymer. The SAN can comprise, for example, 75wt. % styrene and 25 wt. % acrylonitrile based on the total weight ofthe copolymer. An antidrip agent, such as TSAN, can be used in amountsof 0.1 to 10 parts by weight, based on 100 parts by weight of the totalcomposition, excluding any filler.

Additionally, additives to improve flow and other properties may beadded to the composition, such as low molecular weight hydrocarbonresins. These materials are also known as process aids. Particularlyuseful classes of low molecular weight hydrocarbon resins are thosederived from petroleum C₅ to C₉ feedstock that are derived fromunsaturated C₅ to C₉ monomers obtained from petroleum cracking.Non-limiting examples include olefins, e.g. pentenes, hexenes, heptenesand the like; diolefins, e.g. pentadienes, hexadienes and the like;cyclic olefins and diolefins, e.g. cyclopentene, cyclopentadiene,cyclohexene, cyclohexadiene, methyl cyclopentadiene and the like; cyclicdiolefin dienes, e.g., dicyclopentadiene, methylcyclopentadiene dimerand the like; and aromatic hydrocarbons, e.g. vinyltoluenes, indenes,methylindenes and the like. The resins can additionally be partially orfully hydrogenated.

Properties and Articles

The polycarbonate compositions described herein may be used to formrobust flame retardant having improved multi-axial impact strength andnotched impact strength.

In certain aspects of the present disclosure, the combination of apolycarbonate composition, a non-bromine or non-chlorine flameretardant, a non-bonding glass fiber filler, and certain types ofstabilizers may further improve mechanical properties, such asmulti-axial impact strength, while maintaining flame retardantperformance when compared to a substantially similar composition.

Non-bonding glass fiber may provide a higher impact strength (both MAIand notched Izod) than bonding (or binding) glass fiber used as thefiber filler in a substantially similar polycarbonate composition butfor the identity of the glass fiber filler (or, but for the bondingcharacteristics of the glass fiber filler). While a polycarbonatecomposition comprising the non-bonding glass fiber instead of thebonding glass fiber may exhibit improved impact strength, its flameretardant properties may be less robust. For example, a polycarbonatecomposition comprising non-bonding glass fiber may exhibit a longerflame out time (FOT) and improved probability of first time pass (pFTP)or flammability (V) value. Surprisingly, compositions of the presentdisclosure combine certain stabilizer additives with the improved impactstrength properties afforded by the non-bonding glass fiber to providepolycarbonate compositions having improved multi-axial impact strengthas well as robust flame retardant performance.

Compositions of the present disclosure exhibit a synergy amongnon-bonding glass fiber and stabilizers butyl tosylate andtris-(2,4-di-tert-butylphenyl)phosphite. A disclosed compositioncomprising non-bonding glass fiber, butyl tosylate andtris-(2,4-di-tert-butylphenyl)phosphite may exhibit higher MAI strengthvalues tested in accordance with ISO6603 and shorter flame out times(FOT) tested in accordance UL 94 when compared to a substantiallysimilar composition comprising a bonding glass fiber filler. Here, asubstantially similar composition comprising bonding glass fiber fillermay refer to a composition comprising at least the polycarbonatecomponent, the bonding glass fiber filler, the butyl tosylate and thetris-(2,4-di-tert-butylphenyl)phosphite in the absence of a non-bondingglass fiber. A ratio of butyl tosylate totris-(2,4-di-tert-butylphenyl)phosphite in compositions of the presentdisclosure may be from about 1:3 to about 1:50, specifically, from about1:6 to about 1:17. A ratio of butyl tosylate to non-bonding glass fibermay be from about 1:750 to about 1:6000, more specifically from about1:1000 to about 1:3000. A ratio of butyl tosylate to non-bonding glassfiber to tris-(2,4-di-tert-butylphenyl)phosphite may be about 1:10:2000.

In further aspects, compositions of the present disclosure exhibit asynergy between a non-bonding glass fiber and certain phosphitestabilizers. For example, a disclosed composition comprising non-bondingglass fiber and a bis (2,4-dicumylphenyl) pentaerythritol diphosphitestabilizer may exhibit higher MAI strength values tested in accordancewith ISO6603 and shorter flame out times (FOT) when tested in accordanceUL 94 when compared to a substantially similar composition comprising abonding glass fiber filler. Here, a substantially similar compositioncomprising bonding glass fiber filler may refer to a compositioncomprising at least the polycarbonate component, the bonding glass fiberfiller, and the a bis (2,4-dicumylphenyl) pentaerythritol diphosphite(or the tetrakis(2,4-di-tert-butylphenyl)-4,4-diphenyldiphosphonite)) inthe absence of a non-bonding glass fiber. A ratio of non-bonding glassfiber to tetrakis(2,4-di-tert-butylphenyl)-4,4-diphenyldiphosphonite incompositions of the present disclosure may be about 200:1. A ratio ofnon-bonding glass fiber to bis (2,4-dicumylphenyl) pentaerythritoldiphosphite in compositions of the present disclosure may be about200:1.

In specific examples, butyl tosylate as an acid stabilizer andtris-(2,4-di-tert-butylphenyl) phosphite as a heat stabilizer have beencombined with non-bonding glass fiber and a non-bromine/non-chlorine FR(Rimar salt) to provide a polycarbonate composition exhibiting improvedMAI strength and robust flame retardant performance. These disclosedcompositions, in the absence of talc, exhibited better FR and MAIproperties than a substantially similar polycarbonate composition havinga bonding glass fiber and/or in the absence of butyl tosylate. Morespecifically, the disclosed compositions exhibited an MAI punctureenergy of greater than about 70 J at 23° C. when tested in accordancewith ISO 6603, an energy at max for of greater than about 65 J at 23° C.when tested in accordance with ISO 6603, an impact strength of greaterthan about 10 kJ/m² when tested in accordance with ISO 6603, a flame outtime (FOT) of less than about 60 seconds and 0% burning drips for 0.8 mmmolded samples when tested in accordance with UL 94.

The properties of the disclosed polycarbonate compositions make themuseful in a number of applications. The polycarbonate compositions maybe particularly useful in applications where: thin-walled (less than 1mm) flame retardancy, thin-walled notched impact strength, thin-walledmulti-axial impact strength, and bromine-free/chlorine-free formulationsare desired. Thus, the disclosed polycarbonate composition may be usefulfor electrical applications such as use as electrical device enclosures.The improved thin-walled MAI strength of the present disclosure may beeven more useful for electrical device enclosures. MAI strength However,the disclosed polycarbonate compositions are not limited to theforegoing uses. The advantageous mechanical characteristics of thepolycarbonate compositions disclosed herein can make them appropriatefor an array of uses and the compositions may be used to provide anydesired shaped, formed, or molded articles.

Suitable articles can be exemplified by, but are not limited to,aircraft and automotive vehicles, light fixtures and appliances, solarappliances; and like applications. The disclosure further contemplatesadditional fabrication operations on said articles, such as, but notlimited to, molding, in-mold decoration, baking in a paint oven,lamination, and/or thermoforming. The articles made from the compositionof the present disclosure may be used widely in automotive industry,home appliances, electrical components, and telecommunications.

In certain aspects, the present disclosure pertains to electrical orelectronic devices comprising the thermoplastic compositions describedherein. In a further aspect, the electrical or electronic devicecomprising the disclosed thermoplastic compositions can be a cellphone,a MP3 player, a computer, a laptop, a camera, a video recorder, anelectronic tablet, a pager, a hand receiver, a video game, a calculator,circuit boards, a wireless car entry device, wireless devices, audiodevices, scanner fax devices, an automotive part, a filter housing, aluggage cart, an office chair, a kitchen appliance, a display screen orfilm, an electrical housing or enclosure, an electrical connector, alighting fixture, a light emitting diode, an electrical part, or atelecommunications part, among many others.

In a still further aspect, the thermoplastic compositions can also bepresent in overlapping fields, such as mechatronic systems thatintegrate mechanical and electrical properties which can, for example,be used in automotive or medical engineering. In various aspects, thepresent disclosure relates to articles comprising the compositionsherein. The compositions may be molded into useful shaped articles by avariety of means such as injection molding, extrusion, rotationalmolding, blow molding and thermoforming to form articles. Thethermoplastic compositions can be useful in the manufacture of articlesrequiring materials with thin wall flame retardancy and good impactstrength.

In various aspects, the polycarbonate compositions may be preparedaccording to a variety of methods. The compositions of the presentdisclosure can be blended, compounded, or otherwise combined with theaforementioned ingredients by a variety of methods involving intimateadmixing of the materials with any additional additives desired in theformulation. Because of the availability of melt blending equipment incommercial polymer processing facilities, melt processing methods can beused. In various further aspects, the equipment used in such meltprocessing methods can include, but is not limited to, the following:co-rotating and counter-rotating extruders, single screw extruders,co-kneaders, disc-pack processors and various other types of extrusionequipment. In a further aspect, the extruder is a twin-screw extruder.In various further aspects, the composition may processed in an extruderat temperatures from about 180° C. to about 350° C.

In a further aspect, the resulting disclosed compositions can be used toprovide any desired shaped, formed, or molded articles. For example, thedisclosed compositions can be molded into useful shaped articles by avariety of means such as injection molding, extrusion, rotationalmolding, blow molding and thermoforming. As noted above, the disclosedcompositions are particularly well suited for use in the manufacture ofelectronic components and devices. As such, according to some aspects,the disclosed compositions can be used to form articles such as printedcircuit board carriers, burn in test sockets, flex brackets for harddisk drives, and the like.

Aspects

In various aspects, the present invention pertains to and includes atleast the following aspects.

Aspect 1A. A composition comprising: from about 70 wt. % to about 98 wt.% of a polycarbonate polymer component; from about 0.01 to about 1 wt. %of a flame retardant additive, wherein the flame retardant additive isfree or substantially free of bromine and/or chlorine; and from about 2to about 20 wt. % of a non-bonding glass fiber; from about 0.001 toabout 5 wt. % of a stabilizer additive component, wherein the stabilizeradditive component comprises butyl tosylate, wherein a molded sampleformed from the composition exhibits a multi-axial impact (MAI) ratingenergy at max force of greater than about 60 Joules when tested inaccordance with ISO6603 standard and wherein a molded sample of thecomposition achieves a V1 rating at a thickness of about 0.8 millimeter(mm) and a flame out time of less than about 60 seconds when tested inaccordance with UL 94.

Aspect 1B. A composition consisting of: from about 70 wt. % to about 98wt. % of a polycarbonate polymer component; from about 0.01 to about 1wt. % of a flame retardant additive, wherein the flame retardantadditive is free or substantially free of bromine and/or chlorine; andfrom about 2 to about 20 wt. % of a non-bonding glass fiber; from about0.001 to about 5 wt. % of a stabilizer additive component, wherein thestabilizer additive component comprises butyl tosylate, wherein a moldedsample formed from the composition exhibits a multi-axial impact (MAI)rating energy at max force of greater than about 60 Joules when testedin accordance with ISO6603 standard and wherein a molded sample of thecomposition achieves a V1 rating at a thickness of about 0.8 millimeter(mm) and a flame out time of less than about 60 seconds when tested inaccordance with UL 94.

Aspect 1C. A composition consisting essentially of: from about 70 wt. %to about 98 wt. % of a polycarbonate polymer component; from about 0.01to about 1 wt. % of a flame retardant additive, wherein the flameretardant additive is free or substantially free of bromine and/orchlorine; and from about 2 to about 20 wt. % of a non-bonding glassfiber; from about 0.001 to about 5 wt. % of a stabilizer additivecomponent, wherein the stabilizer additive component comprises butyltosylate, wherein a molded sample formed from the composition exhibits amulti-axial impact (MAI) rating energy at max force of greater thanabout 60 Joules when tested in accordance with ISO6603 standard andwherein a molded sample of the composition achieves a V1 rating at athickness of about 0.8 millimeter (mm) and a flame out time of less thanabout 60 seconds when tested in accordance with UL 94.

Aspect 2A. A composition comprising: from about 70 wt. % to about 98 wt.% of a polycarbonate polymer component; from about 0.01 to about 1 wt. %of a flame retardant additive, wherein the flame retardant additive isfree or substantially free of bromine and/or chlorine; and from about 2to about 20 wt. % of a non-bonding glass fiber; from about 0.001 toabout 0.1 wt. % of a stabilizer additive component, wherein thestabilizer additive component comprises butyl tosylate, wherein a moldedsample formed from the composition exhibits a multi-axial impact (MAI)rating energy at max force of greater than about 60 Joules when testedin accordance with ISO6603 standard and wherein a molded sample of thecomposition achieves a V1 rating at a thickness of about 0.8 millimeter(mm) and a flame out time of less than about 60 seconds when tested inaccordance with UL 94.

Aspect 2B. A composition consisting essentially of: from about 70 wt. %to about 98 wt. % of a polycarbonate polymer component; from about 0.01to about 1 wt. % of a flame retardant additive, wherein the flameretardant additive is free or substantially free of bromine and/orchlorine; and from about 2 to about 20 wt. % of a non-bonding glassfiber; from about 0.001 to about 0.1 wt. % of a stabilizer additivecomponent, wherein the stabilizer additive component comprises butyltosylate, wherein a molded sample formed from the composition exhibits amulti-axial impact (MAI) rating energy at max force of greater thanabout 60 Joules when tested in accordance with ISO6603 standard andwherein a molded sample of the composition achieves a V1 rating at athickness of about 0.8 millimeter (mm) and a flame out time of less thanabout 60 seconds when tested in accordance with UL 94.

Aspect 2C. A composition consisting of: from about 70 wt. % to about 98wt. % of a polycarbonate polymer component; from about 0.01 to about 1wt. % of a flame retardant additive, wherein the flame retardantadditive is free or substantially free of bromine and/or chlorine; andfrom about 2 to about 20 wt. % of a non-bonding glass fiber; from about0.001 to about 0.1 wt. % of a stabilizer additive component, wherein thestabilizer additive component comprises butyl tosylate, wherein a moldedsample formed from the composition exhibits a multi-axial impact (MAI)rating energy at max force of greater than about 60 Joules when testedin accordance with ISO6603 standard and wherein a molded sample of thecomposition achieves a V1 rating at a thickness of about 0.8 millimeter(mm) and a flame out time of less than about 60 seconds when tested inaccordance with UL 94.

Aspect 3A. A composition comprising: from about 70 wt. % to about 98 wt.% of a polycarbonate polymer component; from about 0.01 to about 1 wt. %of a flame retardant additive, wherein the flame retardant additive isfree or substantially free of bromine and/or chlorine; and from about 2to about 20 wt. % of a non-bonding glass fiber; from about 0.001 toabout 0.05 wt. % of a stabilizer additive component, wherein thestabilizer additive component comprises butyl tosylate, wherein a moldedsample formed from the composition exhibits a multi-axial impact (MAI)rating energy at max force of greater than about 60 Joules when testedin accordance with ISO6603 standard and wherein a molded sample of thecomposition achieves a V1 rating at a thickness of about 0.8 millimeter(mm) and a flame out time of less than about 60 seconds when tested inaccordance with UL 94.

Aspect 3B. A composition consisting of: from about 70 wt. % to about 98wt. % of a polycarbonate polymer component; from about 0.01 to about 1wt. % of a flame retardant additive, wherein the flame retardantadditive is free or substantially free of bromine and/or chlorine; andfrom about 2 to about 20 wt. % of a non-bonding glass fiber; from about0.001 to about 0.05 wt. % of a stabilizer additive component, whereinthe stabilizer additive component comprises butyl tosylate, wherein amolded sample formed from the composition exhibits a multi-axial impact(MAI) rating energy at max force of greater than about 60 Joules whentested in accordance with ISO6603 standard and wherein a molded sampleof the composition achieves a V1 rating at a thickness of about 0.8millimeter (mm) and a flame out time of less than about 60 seconds whentested in accordance with UL 94.

Aspect 3C. A composition consisting essentially of: from about 70 wt. %to about 98 wt. % of a polycarbonate polymer component; from about 0.01to about 1 wt. % of a flame retardant additive, wherein the flameretardant additive is free or substantially free of bromine and/orchlorine; and from about 2 to about 20 wt. % of a non-bonding glassfiber; from about 0.001 to about 0.05 wt. % of a stabilizer additivecomponent, wherein the stabilizer additive component comprises butyltosylate, wherein a molded sample formed from the composition exhibits amulti-axial impact (MAI) rating energy at max force of greater thanabout 60 Joules when tested in accordance with ISO6603 standard andwherein a molded sample of the composition achieves a V1 rating at athickness of about 0.8 millimeter (mm) and a flame out time of less thanabout 60 seconds when tested in accordance with UL 94.

Aspect 4. The composition of any of aspects 1A-3C, wherein thestabilizer additive component comprises butyl tosylate and a phosphorousbased heat stabilizer.

Aspect 5. The composition of any of aspects 1A-3C, wherein thestabilizer additive component comprises butyl tosylate andtris(di-t-butylphenylphosphite).

Aspect 6. The composition of any of aspects 1A-5, wherein the butyltosylate and non-bonding glass fiber are present in a ratio of fromabout 1:750 to about 1:6000 of butyl tosylate to non-bonding glassfiber.

Aspect 7. The composition of any of aspects 1A-5, wherein the butyltosylate and non-bonding glass fiber are present in a ratio of fromabout 1:1000 to about 1:3000 of butyl tosylate to non-bonding glassfiber.

Aspect 8. The composition of any of aspects 1A-5, wherein the butyltosylate and non-bonding glass fiber are present in a ratio of about1:1200 butyl tosylate to non-bonding glass fiber.

Aspect 9. The composition of any of aspects 1A-5, wherein the butyltosylate and non-bonding glass fiber are present in a ratio of about1:3100 butyl tosylate to non-bonding glass fiber.

Aspect 10. The composition of any of aspects 1A-9, further comprisingstyrene encapsulated polytetrafluoroethylene.

Aspect 11. The composition of aspect 10, wherein the styreneencapsulated polytetrafluoroethylene is present an amount of from about0.1 wt. % to about 1 wt. %.

Aspect 12. The composition of aspect 10, wherein the styreneencapsulated polytetrafluoroethylene is present an amount of from about0.3 wt. % to about 0.7 wt. %.

Aspect 13. The composition of aspect 10, wherein the styreneencapsulated polytetrafluoroethylene is present an amount of about 0.5wt. %.

Aspect 14. A composition comprising: from about 70 wt. % to about 98 wt.% of a polycarbonate polymer component; from about 0.01 wt. % to about 1wt. % of a flame retardant additive, wherein the flame retardantadditive is free or substantially free of bromine and/or chlorine; fromabout 2 wt. % to about 20 wt. % of a non-bonding glass fiber; and fromabout 0.01 wt. % to about 5 wt. % of a stabilizer component wherein thestabilizer component comprises one or more of bis (2,4-dicumylphenyl)pentaerythritol diphosphite ortetrakis(2,4-di-tert-butylphenyl)-4,4-biphenyldiphosphonite (PEPQ),wherein a molded sample formed from the composition exhibits a MAIrating energy at max force of greater than about 60 Joules at 23 degreesCelsius (° C.) when tested in accordance with ISO6603 standard andwherein a molded sample of the composition achieves a V2 rating at athickness of about 0.8 mm UL 94.

Aspect 15. A composition comprising: from about 70 wt. % to about 98 wt.% of a polycarbonate polymer component; from about 0.01 wt. % to about 1wt. % of a flame retardant additive, wherein the flame retardantadditive is free or substantially free of bromine and/or chlorine; fromabout 5 wt. % to about 15 wt. % of a non-bonding glass fiber; and fromabout 0.01 wt. % to about 1 wt. % of a stabilizer component wherein thestabilizer component comprises one or more of bis (2,4-dicumylphenyl)pentaerythritol diphosphite ortetrakis(2,4-di-tert-butylphenyl)-4,4-biphenyldiphosphonite (PEPQ),wherein a molded sample formed from the composition exhibits a MAIrating energy at max force of greater than about 60 Joules at 23 degreesCelsius (° C.) when tested in accordance with ISO6603 standard andwherein a molded sample of the composition achieves a V2 rating at athickness of about 0.8 mm UL 94.

Aspect 16. The composition of aspects 15A-C, wherein a ratio ofnon-bonding glass fiber to bis (2,4-dicumylphenyl) pentaerythritoldiphosphite is from about 180:1 to about 210:1.

Aspect 17. The composition of aspects 15A-C, wherein a ratio ofnon-bonding glass fiber totetrakis(2,4-di-tert-butylphenyl)-4,4-biphenyldiphosphonite is fromabout 180:1 to about 210:1.

Aspect 18. The composition of any of aspects 1A-17, further comprisingone or more additional additives.

Aspect 19. The composition of aspect 18, wherein the one or moreadditional additives comprise a plasticizer, an anti-static agent, animpact modifier, a colorant, an antioxidant, a mold release agent, an UVabsorber, a lubricant, or a blowing agent, or a combination thereof.

Aspect 20. The composition of any one of aspects 1A-19, wherein thenon-bonding glass fiber has a width of from about 10 micrometer (μm) toabout 15 μm.

Aspect 21. The composition of any one of aspects 1A-20, wherein thenon-bonding glass fiber has a length of from about 2 mm to about 6 mm.

Aspect 22. The composition of any one of aspects 1A-21, wherein thenon-bonding glass fiber has a diameter or a width of about 13 μm and alength of 4 mm.

Aspect 23. The composition of any one of aspects 1A-22, wherein theflame retardant additive comprises potassium perfluorobutanesulfonate.

Aspect 24. The composition of any of one of aspects 1A-23, wherein thepolycarbonate polymer component comprises one or more polycarbonatepolymers derived from bisphenol A.

Aspect 25. The composition of any one of aspects 1A-24, wherein thepolycarbonate polymer component comprises a polycarbonate having anaverage molecular weight of from about 18,000 grams per mole to about35,000 grams per mole.

Aspect 26. The composition of any one of aspects 1A-25, wherein thepolycarbonate polymer component comprises a polycarbonate having anaverage molecular weight of from about 18,000 grams per mole to about35,000 grams per mole.

Aspect 27. A method of forming the composition of any one of aspects1A-26.

Aspect 28. A method of forming a composition comprising: from about 70wt. % to about 98 wt. % of a polycarbonate polymer component; from about0.01 to about 1 wt. % of a flame retardant additive, wherein the flameretardant additive is free or substantially free of bromine and/orchlorine; and from about 2 to about 20 wt. % of a non-bonding glassfiber; and from about 0.001 to about 5 wt. % of a stabilizer additivecomponent, wherein the stabilizer additive component comprises butyltosylate, wherein the butyl tosylate and non-bonding glass fiber arepresent in a ratio of from about from about 1:1000 to about 1:3000 ofbutyl tosylate to non-bonding glass fiber.

Aspect 29. A method of forming a composition comprising: from about 70wt. % to about 98 wt. % of a polycarbonate polymer component; from about0.01 to about 1 wt. % of a flame retardant additive, wherein the flameretardant additive is free or substantially free of bromine and/orchlorine; and from about 2 to about 20 wt. % of a non-bonding glassfiber; and from about 0.001 to about 0.1 wt. % of a stabilizer additivecomponent, wherein the stabilizer additive component comprises butyltosylate, wherein the butyl tosylate and non-bonding glass fiber arepresent in a ratio of from about from about 1:1000 to about 1:3000 ofbutyl tosylate to non-bonding glass fiber.

Aspect 30. A method of forming a composition comprising (consisting ofor consisting essentially of): from about 70 wt. % to about 98 wt. % ofa polycarbonate polymer component; from about 0.01 to about 1 wt. % of aflame retardant additive, wherein the flame retardant additive is freeor substantially free of bromine and/or chlorine; and from about 2 toabout 20 wt. % of a non-bonding glass fiber; and from about 0.001 toabout 0.05 wt. % of a stabilizer additive component, wherein thestabilizer additive component comprises butyl tosylate, wherein thebutyl tosylate and non-bonding glass fiber are present in a ratio offrom about from about 1:1000 to about 1:3000 of butyl tosylate tonon-bonding glass fiber.

Aspect 31. The method of aspect 30, wherein a molded sample formed fromthe composition exhibits a MAI rating energy at max force of greaterthan about 60 Joules when tested in accordance with ISO6603 standard,and wherein a molded sample of the composition achieves a V1 rating at athickness of about 0.8 mm and a flame out time of less than about 60seconds when tested in accordance with UL 94.

Aspect 32A. A composition comprising: from about 75 wt. % to about 99wt. % of a polycarbonate polymer component; from about 0.01 to about 1wt. % of a flame retardant additive, wherein the flame retardantadditive is free or substantially free of bromine and/or chlorine; andfrom about 2 to about 20 wt. % of a non-bonding glass fiber; from about0.001 to about 5 wt. % of a stabilizer additive component, wherein thestabilizer additive component comprises butyl tosylate, wherein a moldedsample formed from the composition exhibits a multi-axial impact (MAI)rating energy at max force of greater than about 60 Joules when testedin accordance with ISO6603 standard and wherein a molded sample of thecomposition achieves a V1 rating at a thickness of about 0.8 millimeter(mm) and a flame out time of less than about 60 seconds when tested inaccordance with UL 94.

Aspect 32B. A composition consisting essentially of: from about 75 wt. %to about 99 wt. % of a polycarbonate polymer component; from about 0.01to about 1 wt. % of a flame retardant additive, wherein the flameretardant additive is free or substantially free of bromine and/orchlorine; and from about 2 to about 20 wt. % of a non-bonding glassfiber; from about 0.001 to about 5 wt. % of a stabilizer additivecomponent, wherein the stabilizer additive component comprises butyltosylate, wherein a molded sample formed from the composition exhibits amulti-axial impact (MAI) rating energy at max force of greater thanabout 60 Joules when tested in accordance with ISO6603 standard andwherein a molded sample of the composition achieves a V1 rating at athickness of about 0.8 millimeter (mm) and a flame out time of less thanabout 60 seconds when tested in accordance with UL 94.

Aspect 32C. A composition consisting of: from about 75 wt. % to about 99wt. % of a polycarbonate polymer component; from about 0.01 to about 1wt. % of a flame retardant additive, wherein the flame retardantadditive is free or substantially free of bromine and/or chlorine; andfrom about 2 to about 20 wt. % of a non-bonding glass fiber; from about0.001 to about 5 wt. % of a stabilizer additive component, wherein thestabilizer additive component comprises butyl tosylate, wherein a moldedsample formed from the composition exhibits a multi-axial impact (MAI)rating energy at max force of greater than about 60 Joules when testedin accordance with ISO6603 standard and wherein a molded sample of thecomposition achieves a V1 rating at a thickness of about 0.8 millimeter(mm) and a flame out time of less than about 60 seconds when tested inaccordance with UL 94.

Aspect 33A. A composition comprising: from about 80 wt. % to about 99wt. % of a polycarbonate polymer component; from about 0.01 to about 1wt. % of a flame retardant additive, wherein the flame retardantadditive is free or substantially free of bromine and/or chlorine; andfrom about 2 to about 20 wt. % of a non-bonding glass fiber; from about0.001 to about 5 wt. % of a stabilizer additive component, wherein thestabilizer additive component comprises butyl tosylate, wherein a moldedsample formed from the composition exhibits a multi-axial impact (MAI)rating energy at max force of greater than about 60 Joules when testedin accordance with ISO6603 standard and wherein a molded sample of thecomposition achieves a V1 rating at a thickness of about 0.8 millimeter(mm) and a flame out time of less than about 60 seconds when tested inaccordance with UL 94.

Aspect 33B. A composition consisting essentially of: from about 80 wt. %to about 99 wt. % of a polycarbonate polymer component; from about 0.01to about 1 wt. % of a flame retardant additive, wherein the flameretardant additive is free or substantially free of bromine and/orchlorine; and from about 2 to about 20 wt. % of a non-bonding glassfiber; from about 0.001 to about 5 wt. % of a stabilizer additivecomponent, wherein the stabilizer additive component comprises butyltosylate, wherein a molded sample formed from the composition exhibits amulti-axial impact (MAI) rating energy at max force of greater thanabout 60 Joules when tested in accordance with ISO6603 standard andwherein a molded sample of the composition achieves a V1 rating at athickness of about 0.8 millimeter (mm) and a flame out time of less thanabout 60 seconds when tested in accordance with UL 94.

Aspect 33C. A composition consisting of: from about 80 wt. % to about 99wt. % of a polycarbonate polymer component; from about 0.01 to about 1wt. % of a flame retardant additive, wherein the flame retardantadditive is free or substantially free of bromine and/or chlorine; andfrom about 2 to about 20 wt. % of a non-bonding glass fiber; from about0.001 to about 5 wt. % of a stabilizer additive component, wherein thestabilizer additive component comprises butyl tosylate, wherein a moldedsample formed from the composition exhibits a multi-axial impact (MAI)rating energy at max force of greater than about 60 Joules when testedin accordance with ISO6603 standard and wherein a molded sample of thecomposition achieves a V1 rating at a thickness of about 0.8 millimeter(mm) and a flame out time of less than about 60 seconds when tested inaccordance with UL 94.

Aspect 34. A composition comprising: from about 70 wt. % to about 95 wt.% of a polycarbonate polymer component; from about 0.01 to about 1 wt. %of a flame retardant additive, wherein the flame retardant additive isfree or substantially free of bromine and/or chlorine; and from about 2to about 20 wt. % of a non-bonding glass fiber; from about 0.001 toabout 5 wt. % of a stabilizer additive component, wherein the stabilizeradditive component comprises butyl tosylate, wherein a molded sampleformed from the composition exhibits a multi-axial impact (MAI) ratingenergy at max force of greater than about 60 Joules when tested inaccordance with ISO6603 standard and wherein a molded sample of thecomposition achieves a V1 rating at a thickness of about 0.8 millimeter(mm) and a flame out time of less than about 60 seconds when tested inaccordance with UL 94.

Aspect 34B. A composition consisting essentially of: from about 70 wt. %to about 95 wt. % of a polycarbonate polymer component; from about 0.01to about 1 wt. % of a flame retardant additive, wherein the flameretardant additive is free or substantially free of bromine and/orchlorine; and from about 2 to about 20 wt. % of a non-bonding glassfiber; from about 0.001 to about 5 wt. % of a stabilizer additivecomponent, wherein the stabilizer additive component comprises butyltosylate, wherein a molded sample formed from the composition exhibits amulti-axial impact (MAI) rating energy at max force of greater thanabout 60 Joules when tested in accordance with ISO6603 standard andwherein a molded sample of the composition achieves a V1 rating at athickness of about 0.8 millimeter (mm) and a flame out time of less thanabout 60 seconds when tested in accordance with UL 94.

Aspect 34C. A composition consisting of: from about 70 wt. % to about 95wt. % of a polycarbonate polymer component; from about 0.01 to about 1wt. % of a flame retardant additive, wherein the flame retardantadditive is free or substantially free of bromine and/or chlorine; andfrom about 2 to about 20 wt. % of a non-bonding glass fiber; from about0.001 to about 5 wt. % of a stabilizer additive component, wherein thestabilizer additive component comprises butyl tosylate, wherein a moldedsample formed from the composition exhibits a multi-axial impact (MAI)rating energy at max force of greater than about 60 Joules when testedin accordance with ISO6603 standard and wherein a molded sample of thecomposition achieves a V1 rating at a thickness of about 0.8 millimeter(mm) and a flame out time of less than about 60 seconds when tested inaccordance with UL 94.

Aspect 35. A composition comprising: from about 70 wt. % to about 98 wt.% of a polycarbonate polymer component; from about 0.01 to about 1 wt. %of a flame retardant additive, wherein the flame retardant additive isfree or substantially free of bromine and/or chlorine; and from about 2to about 10 wt. % of a non-bonding glass fiber; from about 0.001 toabout 5 wt. % of a stabilizer additive component, wherein the stabilizeradditive component comprises butyl tosylate, wherein a molded sampleformed from the composition exhibits a multi-axial impact (MAI) ratingenergy at max force of greater than about 60 Joules when tested inaccordance with ISO6603 standard and wherein a molded sample of thecomposition achieves a V1 rating at a thickness of about 0.8 millimeter(mm) and a flame out time of less than about 60 seconds when tested inaccordance with UL 94.

Aspect 35. A composition consisting essentially of: from about 70 wt. %to about 98 wt. % of a polycarbonate polymer component; from about 0.01to about 1 wt. % of a flame retardant additive, wherein the flameretardant additive is free or substantially free of bromine and/orchlorine; and from about 2 to about 10 wt. % of a non-bonding glassfiber; from about 0.001 to about 5 wt. % of a stabilizer additivecomponent, wherein the stabilizer additive component comprises butyltosylate, wherein a molded sample formed from the composition exhibits amulti-axial impact (MAI) rating energy at max force of greater thanabout 60 Joules when tested in accordance with ISO6603 standard andwherein a molded sample of the composition achieves a V1 rating at athickness of about 0.8 millimeter (mm) and a flame out time of less thanabout 60 seconds when tested in accordance with UL 94.

Aspect 35. A composition consisting of: from about 70 wt. % to about 98wt. % of a polycarbonate polymer component; from about 0.01 to about 1wt. % of a flame retardant additive, wherein the flame retardantadditive is free or substantially free of bromine and/or chlorine; andfrom about 2 to about 10 wt. % of a non-bonding glass fiber; from about0.001 to about 5 wt. % of a stabilizer additive component, wherein thestabilizer additive component comprises butyl tosylate, wherein a moldedsample formed from the composition exhibits a multi-axial impact (MAI)rating energy at max force of greater than about 60 Joules when testedin accordance with ISO6603 standard and wherein a molded sample of thecomposition achieves a V1 rating at a thickness of about 0.8 millimeter(mm) and a flame out time of less than about 60 seconds when tested inaccordance with UL 94.

Examples

Detailed embodiments of the present disclosure are disclosed herein; itis to be understood that the disclosed embodiments are merely exemplaryof the disclosure that may be embodied in various forms. Therefore,specific structural and functional details disclosed herein are not tobe interpreted as limits, but merely as a basis for teaching one skilledin the art to employ the present disclosure. The specific examples belowwill enable the disclosure to be better understood. However, they aregiven merely by way of guidance and do not imply any limitation.

The following examples are provided to illustrate the compositions,processes, and properties of the present disclosure. The examples aremerely illustrative and are not intended to limit the disclosure to thematerials, conditions, or process parameters set forth therein.

General Materials and Methods

The compositions as set forth in the Examples below were prepared fromthe components described below. Table 1 shown in FIG. 1 presents typesof polymers, additives, and glass fiber filler used.

Table 2 shown in FIG. 2 provides additional detail for characteristicsof the glass fibers used including the dimensions of the fibers as wellas the type of polymer to which the fiber is conventionally added.

Formulations were prepared by extrusion on a 25 mm twin screw extruder(Krupps Werner and Plefeiderer), according to the extrusion profileindicated in Table 3. All powders were blended using a paint shaker andfed through one feeder. The remaining PC was fed through a secondfeeder. The glass fiber was fed separately through the hopper or adownstream side-feeder. The extrudate was cooled using a water bathprior to pelletizing.

TABLE 3 Compounding Settings Extruder Die Units Zone 1 Temp ° C. 180Zone 2 Temp ° C. 250 Zone 3 Temp ° C. 270 Zone 4 Temp ° C. 285 Zone 5Temp ° C. 285 Zone 6 Temp ° C. 285 Zone 7 Temp ° C. 285 Zone 8 Temp ° C.285 Zone 9 Temp ° C. 285 Die Temp ° C. 285 Screw speed rpm 300Throughput kg/hr 18

The pellets obtained from extrusion were dried at 120° C. for two hours.Molding of 3 mm ISO parts (Izod bars, plaques) of UL bars was performedon an Engel® 75T molding machine. The injection molding parameters areset forth in Table 4.

TABLE 4 Injection molding settings. Molding Machine Cnd: Pre-drying timeHour 2 Cnd: Pre-drying temp ° C. 120 Hopper temp ° C. 40 Zone 1 temp °C. 280 Zone 2 temp ° C. 290 Zone 3 temp ° C. 300 Nozzle temp ° C. 295Mold temp ° C. 90 Screw speed rpm 100 Back pressure kgf/cm² 5

Molded samples were then tested in accordance with the standardspresented below.

The notched Izod impact (“NII”) test was carried out on 80 mm×10 mm×3 mmmolded samples (bars) with 2 mm notch, according to ISO180 at 0° C.,−30° C. and 23° C. Data units are kJ/m².

Multi-axial impact (MAI) strength testing was performed according toISO0633 at 0° C., −30° C. and 23° C. on disk specimens having a 100 mmdiameter and a thickness of 3.2 mm with a speed of 4.4 meters per second(m/s).

Flammability tests were performed following the procedure ofUnderwriter's Laboratory Bulletin 94 entitled “Tests for Flammability ofPlastic Materials, UL 94”. Several ratings can be applied based on therate of burning, time to extinguish, ability to resist dripping, andwhether or not drips are burning. Specimens for testing were injectionmolded bars comprising of the injection molded thermoplasticcomposition. Each specimen had a thickness of either 0.8 millimeters(mm), 1.5 mm, or mm. Materials can be classified according to thisprocedure as UL 94 vertical burn (V0, V1, V2) on the basis of the testresults obtained for five samples.

V0: In a sample placed so that its long axis is 180 degrees to theflame, the period of flaming and/or smoldering after removing theigniting flame does not exceed ten (10) seconds and the verticallyplaced sample produces no drips of burning particles that igniteabsorbent cotton. Five bar flame out time is the flame out time for fivebars, each lit twice, in which the sum of time to flame out for thefirst (t1) and second (t2) ignitions is less than or equal to a maximumflame out time (t1+t2) of 50 seconds.

V1: In a sample placed so that its long axis is 180 degrees to theflame, the period of flaming and/or smoldering after removing theigniting flame does not exceed thirty (30) seconds and the verticallyplaced sample produces no drips of burning particles that igniteabsorbent cotton. Five bar flame out time is the flame out time for fivebars, each lit twice, in which the sum of time to flame out for thefirst (t1) and second (t2) ignitions is less than or equal to a maximumflame out time (t1+t2) of 250 seconds.

V2: In a sample placed so that its long axis is 180 degrees to theflame, the average period of flaming and/or smoldering after removingthe igniting flame does not exceed thirty (30) seconds, but thevertically placed samples produce drips of burning particles that ignitecotton. Five bar flame out time is the flame out time for five bars,each lit twice, in which the sum of time to flame out for the first (t1)and second (t2) ignitions is less than or equal to a maximum flame outtime (t1+t2) of 250 seconds.

Flame-out-times may be as analyzed and described in U.S. Pat. No.6,308,142 B1. Generally, the data may be analyzed by calculation of theaverage flame out time (avFOTsec). Hours are denoted h.

Samples were evaluated for the effect of the different types of glassfiber on impact strength properties and flame retardant properties.Results are presented in Table 5 in FIG. 3.

As described herein, while a non-bonding glass fiber shows improvedimpact properties, flame retardant properties may be less robust than asubstantially similar composition comprising a bonding an alternativetype of glass fiber. Example 2 (Ex2) comprising the non-bonding glassfiber has consistently higher values for MAI than all other types ofglass fibers observed, that is Comparative examples 1 (CE1), comparativeexample 3 (CE3), comparative example 4 (CE4), Comparative Example 5(Ex5) Comparative Example 6 (Ex6), and Comparative 7 (CE7). CE1comprising the bonding GF exhibited the lowest MAI impact strengthvalues. However, Ex2 had the poorest (longest duration) flame out time(FOT) of the examples observed (at 117 seconds at 23° C. for 0.8millimeter thick molded samples). The thicker 1.5 mm sample for Ex. 2exhibited the lowest FOT for samples tested at that thickness.

Samples were then prepared with non-bonding glass fiber and differentcombinations of stabilizer additives and evaluated for impact strengthsand flame retardant properties. Results are presented in Tables 6A and6B in FIG. 4.

CE1 and Ex2 are presented in Table 6 for reference showing that thenon-bonding glass fibers provided better MAI than the bonding GFcounterpart. Ex8 and CE9 introduce heat stabilizer butyl tosylate(BuTos) to the non-bonding glass fiber and acid stabilizer combinationand show that the BuTos containing sample performed better withnon-bonding glass fiber than with bonding glass fiber. Multi-axialimpact and notched impact strength values increased while maintainingflame retardant properties (FOT) within 5% and burning drips at 0%. TheFOT for Ex 8 are also reduced from 117 seconds observed for Ex2 and from88.9 s observed for CE9. Example 10 further improved these properties byincreasing the amount of BuTos. The all color V1 rating of Ex8 has beenverified by UL certified lab under the experimental grade name,ER007338.

Comparative examples 10 (CE10) and 11 (CE11) include the non-bondingglass fiber and acid stabilizer Irgafos™ 168 combined with a phosphorousacid stabilizer (H₃PO₃, 45% in water). CE10 exhibited a MAI comparableto Ex2, but the FOT was much higher at 140 seconds. CE11 had a muchlower MAI and a slightly lower, but still long FOT. Comparative Example12 (CE12) increased the amount of phosphorous acid which slightlylowered the thin wall FOT, but also significantly decreased the MAIcompared to CE11. CE11 and CE12 indicate that the combination of Irg168and phosphorous acid do not improve MAI or FOT, and increasingphosphorous acid may negatively affect the MAI performance.

Example 13 (Ex13) and Comparative Example 14 introduce differentphosphorous stabilizer additives, PEPQ and Doverphos S-9228. Ex13 havingthe phosphorous additive PEPQ with non-bonding glass fiber exhibitedhigher MAI and shorter FOT for both 0.8 mm and 1.5 mm samples comparedto the bonding GF CE14. Comparative Example 15 (CE15) and ComparativeExample 16 (CE16) include Doverphos instead of PEPQ. CE15, including thenon-bonding GF exhibited much higher values for the MAI and a shorterFOT when compared to CE16 comprising the bonding GF. When compared toexamples including phosphorous acid (CE11, CE12), the Doverphos S-9228and PEPQ both provide better MAI and FR properties. It may be that thephosphorous acid and the Doverphos S-9228 (or the PEPQ) react with thepolycarbonate in a different way. For example, PEPQ and Doverphos S-9228may react more slowly than the phosphorous acid.

The patentable scope of the disclosure is defined by the claims, and caninclude other examples that occur to those skilled in the art. Suchother examples are intended to be within the scope of the claims if theyhave structural elements that do not differ from the literal language ofthe claims, or if they include equivalent structural elements withinsubstantial differences from the literal languages of the claims.

While aspects of the present disclosure can be described and claimed ina particular statutory class, such as the system statutory class, thisis for convenience only and one of skill in the art will understand thateach aspect of the present invention can be described and claimed in anystatutory class. Unless otherwise expressly stated, it is in no wayintended that any method or aspect set forth herein be construed asrequiring that its steps be performed in a specific order. Accordingly,where a method claim does not specifically state in the claims ordescriptions that the steps are to be limited to a specific order, it isno way intended that an order be inferred, in any respect. This holdsfor any possible non-express basis for interpretation, including mattersof logic with respect to arrangement of steps or operational flow, plainmeaning derived from grammatical organization or punctuation, or thenumber or type of aspects described in the specification.

Moreover, it is to be understood that unless otherwise expressly stated,it is in no way intended that any method set forth herein be construedas requiring that its steps be performed in a specific order.Accordingly, where a method claim does not actually recite an order tobe followed by its steps or it is not otherwise specifically stated inthe claims or descriptions that the steps are to be limited to aspecific order, it is no way intended that an order be inferred, in anyrespect. This holds for any possible non-express basis forinterpretation, including: matters of logic with respect to arrangementof steps or operational flow; plain meaning derived from grammaticalorganization or punctuation; and the number or type of aspects describedin the specification.

It is also to be understood that the terminology used herein is for thepurpose of describing particular aspects only and is not intended to belimiting. As used in the specification and in the claims, the term“comprising” may include the aspects “consisting of” and “consistingessentially of.” Unless defined otherwise, all technical and scientificterms used herein have the same meaning as commonly understood by one ofordinary skill in the art to which this disclosure belongs.

As used in the specification and the appended claims, the singular forms“a,” “an” and “the” include plural referents unless the context clearlydictates otherwise. Thus, for example, reference to “a polycarbonate”includes mixtures of two or more such polycarbonates. Furthermore, forexample, reference to a filler includes mixtures of two or more suchfillers.

Ranges can be expressed herein as from “about” one particular value,and/or to “about” another particular value. When such a range isexpressed, another aspect includes from the one particular value and/orto the other particular value. Similarly, when values are expressed asapproximations, by use of the antecedent “about,” it will be understoodthat the particular value forms another aspect. A value modified by aterm or terms, such as “about” and “substantially,” is intended toinclude the degree of error associated with measurement of theparticular quantity based upon the equipment available at the time offiling this application. It will be further understood that theendpoints of each of the ranges are significant both in relation to theother endpoint, and independently of the other endpoint. It is alsounderstood that there are a number of values disclosed herein, and thateach value is also herein disclosed as “about” that particular value inaddition to the value itself. For example, if the value “10” isdisclosed, then “about 10” is also disclosed. It is also understood thateach unit between two particular units are also disclosed. For example,if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.

As used herein, the terms “optional” or “optionally” mean that thesubsequently described event, condition, component, or circumstance mayor may not occur, and that the description includes instances where saidevent or circumstance occurs and instances where it does not.

Disclosed are component materials to be used to prepare disclosedcompositions as well as the compositions themselves to be used withinmethods disclosed herein. These and other materials are disclosedherein, and it is understood that when combinations, subsets,interactions, groups, etc. of these materials are disclosed that whilespecific reference of each various individual and collectivecombinations and permutation of these compounds cannot be explicitlydisclosed, each is specifically contemplated and described herein. Forexample, if a particular compound is disclosed and discussed and anumber of modifications that can be made to a number of moleculesincluding the compounds are discussed, specifically contemplated is eachand every combination and permutation of the compound and themodifications that are possible unless specifically indicated to thecontrary. Thus, if a class of molecules A, B, and C are disclosed aswell as a class of molecules D, E, and F and an example of a combinationmolecule, A-D is disclosed, then even if each is not individuallyrecited each is individually and collectively contemplated meaningcombinations, A-E, A-F, B-D, B-E, B-F, C-D, C-E, and C-F are considereddisclosed. Likewise, any subset or combination of these is alsodisclosed. Thus, for example, the sub-group of A-E, B-F, and C-E wouldbe considered disclosed. This concept applies to all aspects of thisapplication including, but not limited to, steps in methods of makingand using the compositions of the disclosure. Thus, if there are avariety of additional steps that can be performed it is understood thateach of these additional steps can be performed with any specific aspector combination of aspects of the methods of the disclosure.

References in the specification and concluding claims to parts byweight, of a particular element or component in a composition or articledenotes the weight relationship between the element or component and anyother elements or components in the composition or article for which apart by weight is expressed. Thus, in a composition containing 2 partsby weight of component X and 5 parts by weight component Y, X and Y arepresent at a weight ratio of 2:5, and are present in such ratioregardless of whether additional components are contained in thecompound.

A weight percent of a component, unless specifically stated to thecontrary, is based on the total weight of the formulation or compositionin which the component is included.

Compounds disclosed herein are described using standard nomenclature.For example, any position not substituted by any indicated group isunderstood to have its valency filled by a bond as indicated, or ahydrogen atom. A dash (“-”) that is not between two letters or symbolsis used to indicate a point of attachment for a substituent. Forexample, —CHO is attached through carbon of the carbonyl group. Unlessdefined otherwise, technical and scientific terms used herein have thesame meaning as is commonly understood by one of skill in the art towhich this disclosure belongs.

As used herein, the terms “number average molecular weight” or “Mn” canbe used interchangeably, and refer to the statistical average molecularweight of all the polymer chains in the sample and is defined by theformula:

${Mn} = \frac{\Sigma\; N_{i}M_{i}}{\Sigma\; N_{i}}$${Mn} = \frac{\Sigma\; N_{i}M_{i}}{\Sigma\; N_{i}}$where M_(i) is the molecular weight of a chain and N_(i) is the numberof chains of that molecular weight. Mn can be determined for polymers,such as polycarbonate polymers or polycarbonate-polysiloxane copolymers,by methods well known to a person having ordinary skill in the art.

As used herein, the terms “weight average molecular weight” or “Mw” canbe used interchangeably, and are defined by the formula:

${Mw} = \frac{\Sigma\; N_{i}M_{i}^{2}}{\Sigma\; N_{i}M_{i}}$wherein Mi is the molecular weight of a chain and Ni is the number ofchains of that molecular weight. Compared to Mn, Mw takes into accountthe molecular weight of a given chain in determining contributions tothe molecular weight average. Thus, the greater the molecular weight ofa given chain, the more the chain contributes to the Mw. It is to beunderstood that as used herein, Mw is measured by gel permeationchromatography. In some cases, Mw can be measured by gel permeationchromatography and calibrated with polycarbonate standards. As anexample, a polycarbonate of the present disclosure can have a weightaverage molecular weight of greater than about 5,000 Daltons based on PSstandards. As a further example, the polycarbonate can have an Mw offrom about 20,000 to about 100,000 Daltons.

What is claimed is:
 1. A composition comprising: from about 70 wt. % toabout 98 wt. % of a polycarbonate polymer component; from about 0.01 toabout 1 wt. % of a flame retardant additive, wherein the flame retardantadditive is free or substantially free of bromine and/or chlorine; fromabout 2 to about 20 wt. % of a non-bonding glass fiber; and from about0.001 to about 5 wt. % of a stabilizer additive component, wherein thestabilizer additive component comprises butyl tosylate, wherein thebutyl tosylate and non-bonding glass fiber are present in a ratio offrom about 1:1000 to about 1:3000 of butyl tosylate to non-bonding glassfiber; wherein a molded sample formed from the composition exhibits amulti-axial impact (MAI) rating energy at max force of greater thanabout 60 Joules when tested in accordance with ISO6603 standard andwherein a molded sample of the composition achieves a V1 rating at athickness of about 0.8 millimeter (mm) and a flame out time of less thanabout 60 seconds when tested in accordance with UL 94; wherein theweight percentages are based on the total weigh of the composition. 2.The composition of claim 1, wherein the stabilizer additive componentcomprises butyl tosylate and a phosphorous based heat stabilizer.
 3. Thecomposition of claim 1, wherein the stabilizer additive componentcomprises butyl tosylate and tris(di-t-butylphenylphosphite).
 4. Thecomposition of claim 1, further comprising one or more additionaladditives.
 5. The composition of claim 4, wherein the one or moreadditional additives comprise a plasticizer, an anti-static agent, animpact modifier, a colorant, an antioxidant, a mold release agent, an UVabsorber, a lubricant, or a blowing agent, or a combination thereof. 6.A composition comprising: from about 70 wt. % to about 98 wt. % of apolycarbonate polymer component; from about 0.01 to about 1 wt. % of aflame retardant additive, wherein the flame retardant additive is freeor substantially free of bromine and/or chlorine; from about 2 to about20 wt. % of a non-bonding glass fiber; wherein the non-bonding glassfiber has at least one of a width of from about 10 micrometer (μm) toabout 15 μm, a length of from about 2 mm to about 6 mm, or a diameter ora width of about 13 μm and a length of 4 mm; and from about 0.001 toabout 5 wt. % of a stabilizer additive component, wherein the stabilizeradditive component comprises butyl tosylate, wherein a molded sampleformed from the composition exhibits a multi-axial impact (MAI) ratingenergy at max force of greater than about 60 Joules when tested inaccordance with ISO6603 standard and wherein a molded sample of thecomposition achieves a V1 rating at a thickness of about 0.8 millimeter(mm) and a flame out time of less than about 60 seconds when tested inaccordance with UL 94; wherein the weight percentages are based on thetotal weigh of the composition.
 7. The composition of claim 1, whereinthe non-bonding glass fiber has the length of from about 2 mm to about 6mm.
 8. The composition of claim 1, wherein the non-bonding glass fiberhas the diameter or the width of about 13 μm and the length of 4 mm. 9.The composition of claim 1, wherein the flame retardant additivecomprises potassium perfluorobutanesulfonate.
 10. The composition ofclaim 1, wherein the polycarbonate polymer component comprises one ormore polycarbonate polymers derived from bisphenol A.
 11. Thecomposition of claim 1, wherein the polycarbonate polymer componentcomprises a polycarbonate having an average molecular weight of fromabout 18,000 grams per mole to about 35,000 grams per mole.
 12. Thecomposition of claim 1, wherein the polycarbonate polymer componentcomprises a polycarbonate having an average molecular weight of fromabout 18,000 grams per mole to about 35,000 grams per mole.
 13. Thecomposition of claim 1, further comprising a styrene encapsulatedpolytetrafluoroethylene, wherein the styrene encapsulatedpolytetrafluoroethylene is present in an amount from about 0.2 wt. % toabout 1 wt. %.
 14. A method of forming the composition of claim
 1. 15. Amethod of forming the composition of claim 1 comprising: from about 70wt. % to about 98 wt. % of a polycarbonate polymer component; from about0.01 to about 1 wt. % of a flame retardant additive, wherein the flameretardant additive is free or substantially free of bromine and/orchlorine; and from about 2 to about 20 wt. % of a non-bonding glassfiber; and from about 0.001 to about 5 wt. % of a stabilizer additivecomponent, wherein the stabilizer additive component comprises butyltosylate, wherein the butyl tosylate and non-bonding glass fiber arepresent in a ratio of from about from about 1:1000 to about 1:3000 ofbutyl tosylate to non-bonding glass fiber.
 16. The method of claim 15,wherein a molded sample formed from the composition exhibits a MAIrating energy at max force of greater than about 60 Joules when testedin accordance with ISO6603 standard, and wherein a molded sample of thecomposition achieves a V1 rating at a thickness of about 0.8 mm and aflame out time of less than about 60 seconds when tested in accordancewith UL
 94. 17. A composition comprising: from about 70 wt. % to about98 wt. % of a polycarbonate polymer component; from about 0.01 to about1 wt. % of a flame retardant additive, wherein the flame retardantadditive is free or substantially free of bromine and/or chlorine; fromabout 2 to about 20 wt. % of a non-bonding glass fiber; and from about0.001 to about 5 wt. % of a stabilizer additive component, wherein thestabilizer additive component comprises butyl tosylate, wherein a moldedsample formed from the composition exhibits a multi-axial impact (MAI)rating energy at max force of greater than about 60 Joules when testedin accordance with ISO6603 standard and wherein a molded sample of thecomposition achieves a V1 rating at a thickness of about 0.8 millimeter(mm) and a flame out time of less than about 60 seconds when tested inaccordance with UL 94; wherein at least one of the flame retardantadditive comprises potassium perfluorobutanesulfonate or the compositionfurther comprises a styrene encapsulated polytetrafluoroethylene in anamount from about 0.2 wt. % to about 1 wt. %; wherein the weightpercentages are based on the total weigh of the composition.